Newoldarmy said:
I've just been cutting them off and doing nail knots to make a new loop once they get worn.
Those welded loops are trash, but the way lines are made now makes the nail knot deal hard because the line cover slips on the core.
Definitely either a conspiracy to sell more line or a manufacturing deficit.
Do a nail-knot on the fly line and leave enough of a tag end on the fly line past the nail knot to whip in a half-hitch around the butt section that's nail-knotted. Then trim the excess of the hitch and coat with an epoxy- I use Loon Clear Cure UV Knot-sense.
I have this done on my primary 8, 10, and 12wt rigs. It's probably overkill on the 8wt but whatever.
Here's a how-to video and where I picked it up: https://vimeo.com/82401443