Issue with Breaking Off Second Fly

You mentioned that "there was no evidence of any of the tippet from the dropper fly". This makes me think the 3x is not breaking, but rather the knot is slipping out of the eye. Could the knot be slipping out here?
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Some hooks are notorious for having too big of a gap here.

Could also be a sharp burr where the wire was cut during manufacture, which then cuts your dropper line when it is put under tension.
 
Could also be a sharp burr where the wire was cut during manufacture, which then cuts your dropper line when it is put under tension.
I wondered about the hook eye not being "smooth" - I've had issues with one brand of tippet rings (I used and improved clinch knot when tying the leader and tippet to a tippet ring) where it seems the tippet ring cut or wore the tippet (and once the leader connection).
 
Couple of follow on comments based upon some thoughts posted here.
1. I don't think its in any way the hook eye itself. If that was an issue then I'd be losing the upper fly in some cases and for sure when fishing it as a single. And that just isn't happening.
2. I will not tie the dropper to the hook of a barbless fly. I have lost too many fish doing that.

I do use the method of tying on the upper fly with a long tag end that I then tie the dropper to. But that is only doable when you start out with two flies in the first place. When I already have a fly tied on I just can't fathom cutting it off to retie to give me a long tag end for tying on the second fly. But maybe that would be less frustrating than breaking off the dropper fly.....LOL.

Think the first step is to just make sure I am using no slip loop knots on both flies and see if that reduces the issue.
 
I have definitely lost the dropper off a bad hook eye because the dropper was tied on the hook eye gap side. Is it possible the dropper fly was tied on that side?
You wouldn't lose the upper fly because the dropper knot would block it from slipping thru the gap.
Also, the upper fly typically pulls straighter or more true than a dropper. The upper fly usually stays more in line with the tippet.

When I've had some suspect hook eyes I make sure the dropper knot is on the solid side. I've even clipped off the point/top fly just to re-tie it on the gap side so the dropper is not on the gap side. And some don't have a big enough gap, but like @Chucker mentioned, some hooks have a bad cut resulting in a rough terminal end at that gap.

The only other thing I can think of is maybe your improved clinch knot for the dropper is not quite as good as the point/top fly. I'm not saying you tie crappy knots. Haha! I'm saying I have tied crappy clinch knots on the dropper fly because the tippet to the point/top fly is in play and it's a different angle and all of that. I've tied some very suspect dropper imp clinched knots. It's easy to do.

Keep us updated on how it goes with the loop knots. (y)
 
Couple of follow on comments based upon some thoughts posted here.
1. I don't think its in any way the hook eye itself. If that was an issue then I'd be losing the upper fly in some cases and for sure when fishing it as a single. And that just isn't happening.
2. I will not tie the dropper to the hook of a barbless fly. I have lost too many fish doing that.

I do use the method of tying on the upper fly with a long tag end that I then tie the dropper to. But that is only doable when you start out with two flies in the first place. When I already have a fly tied on I just can't fathom cutting it off to retie to give me a long tag end for tying on the second fly. But maybe that would be less frustrating than breaking off the dropper fly.....LOL.

Think the first step is to just make sure I am using no slip loop knots on both flies and see if that reduces the issue.
You can tie to the line above the knot to your upper fly using a uni knot. That also works for adding a dropper to an existing leader, or replacing a dropper that has become too short.
 
Couple of follow on comments based upon some thoughts posted here.
1. I don't think its in any way the hook eye itself. If that was an issue then I'd be losing the upper fly in some cases and for sure when fishing it as a single. And that just isn't happening.
2. I will not tie the dropper to the hook of a barbless fly. I have lost too many fish doing that.

I do use the method of tying on the upper fly with a long tag end that I then tie the dropper to. But that is only doable when you start out with two flies in the first place. When I already have a fly tied on I just can't fathom cutting it off to retie to give me a long tag end for tying on the second fly. But maybe that would be less frustrating than breaking off the dropper fly.....LOL.

Think the first step is to just make sure I am using no slip loop knots on both flies and see if that reduces the issue.
I have not tried this with fishing line/leaders/tippet, but I wonder if an alpine butterfly knot would work to create a tie in point for a dropper without removing the existing fly?

How to Tie a Butterfly Knot? Uses & Easy Step-By-Step Instructions https://share.google/9PkfI2UUdJTUYp8CU
 
Couple of follow on comments based upon some thoughts posted here.
1. I don't think its in any way the hook eye itself. If that was an issue then I'd be losing the upper fly in some cases and for sure when fishing it as a single. And that just isn't happening.
2. I will not tie the dropper to the hook of a barbless fly. I have lost too many fish doing that.

I do use the method of tying on the upper fly with a long tag end that I then tie the dropper to. But that is only doable when you start out with two flies in the first place. When I already have a fly tied on I just can't fathom cutting it off to retie to give me a long tag end for tying on the second fly. But maybe that would be less frustrating than breaking off the dropper fly.....LOL.

Think the first step is to just make sure I am using no slip loop knots on both flies and see if that reduces the issue.
Yesterday I ran out of tag end and couldn't change my point fly. I cut off the point fly and cut the dropper line at the knot. I then took the dropper line with the fly still attached and tied a new double surgeons with it. New point fly was on and fishing in about 3 minutes.
 
Switch your tippet material to Trouthunter flouro or SA Absolute
 
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