The needle knot
John,
The needle knot where the needle goes through the fly line is tricky exactly for the reason you mention - keeping the hole open while you poke the leader through. Two things help:
1) Use an oversize needle. As you have notice the hole closes anyway, so working the hole larger is usually no problem. I have also worked with a hot needle sometimes, but this requires some delicacy in order not to melt the coating completely. I have also tried pressing the needle through the coating cold and then heating the part outside the fly line. This is easier to control, and makes the hole stay open when the needle is removed after cooling.
2) Cut the leader at an angle with a knife, razor blade or sharp scissors. This forms a tip, which is a lot easier to pass through the newly formed hole. I can read that you have done this already.
If none of this works, consider a nail less nail knot tied on the outside of the line https://globalflyfisher.com/node/13845#nailless or an Albright knot https://globalflyfisher.com/node/25503 (used for backing here, but it works for leaders too) where the fly line is doubled back as shown here.
Tying the thick butt of the leader on to the supple fly line is a menace no matter what, so have patience.
Hope some of this works for you.
Martin
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