I have an Abu Black Max rod. The tiptop insert came out. So I removed the tiptop. It appears to be a size 6. However, it's a bit loose upon trying to replace. I went down to a 5.5, and it's better, but still has a bit of play. Should I go down to a 5, which would probably be a tight slip fit?

 

In other words, do you want any gap at all, or do you want the tip to be as tight as possible?

 

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Other details, 
I've been dealing with this rod and replacing tips on it for a while. I have replaced the tip with another size 6, and with that 5.5, and both of them would eventually twist on the blank during use.

 

I have tried cleaning the blank with alcohol.

Roughing the blank up with scotchbrite pad.

Roughing the inside of the tiptop with fine sandpaper.

2 different glues

3 tiptops

 

Plus, the blank broke just past where the tiptop is, so I had some fresh area to work with, and I've have the same issues there.

No gap means no glue to do the job, if you have a drill set that also has the plastic drill gauge you are in business, drills are also sized in 1/64th inches, if you can't fit it or it doesn't go down far enough you are a half size larger, being too big is way obvious and easy to test by going down one. Sometimes they are free or dirt cheap, much cheaper than the plastic tip top gauges but you can go through a box of tip tops and size them right with a tip top gauge.

Probably the reason the rod broke is too much heat removing or replacing the tip top.  Get a tip top that slips on the rod, not loose, get the heat melt glue that is for tip tops, shave the glue and pack it in the tip top, heat the tip top, not the rod, and push it on while turning it to the right place, finally, with your finger nail clean the excess glue off the rod.