Tom,
Not sure what type of reel your are using now, but have you tried any of the Avet MC style reels or a Newell? I have an old Newell that I learned to cast on, and oh my the free spool on it (back in the '80s) was awesome and it still casts great almost 30 years later. I have also watched some of the current videos on the Avet and I'm impressed. Here is one of them:
http://youtu.be/dmp0JdVDsRE