DIY Aluminum poles

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I often custom cut and assemble aluminum poles for use with my tents and canopies. Replacing fiberglass poles with aluminum can increase strength and reduce weight. Cutting my own poles also allows me to customize the collapsible length for more convenient storage in my backpack.

My first attempt cutting and assembling poles was in order to repair a broken one. Once I realized how easy it is I started making custom poles for many uses and became more efficient at doing so.

Examples of some customized tent and canopy poles:
 

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That is a great idea. Where do you purchase the aluminum pipe and how do you connect them?

I haven't purchased aluminum pole sections in several years but I have sourced them from amazon https://www.amazon.com/Brightfour-R...rds=aluminum+tent+poles&qid=1637460775&sr=8-3 and ebay.

Pole sections are available in various colors, diameters, and aluminum alloys. The pole sections are connected by threading shock cord through them. The shock cord is secured to the end pole sections with a metal washer and overhand knot if using a ring & pin canopy connector. The shock cord is secured to the end pole sections with an overhand knot attached to an end-tip if using a end-tip canopy connector. Non-threaded and threaded end-tips are available.

Google search " aluminum tent pole repair " and you should find videos demonstrating how the poles are configured.
 

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I have an old Wensel dome, that I, and my two sons used in the early days. I should see if I still have it. It had large diameter aluminum poles, that were pre bent. Of course one broke.

Thanks for the heads up on pole repair !

Jim
 
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Jim, it is possible to pre-bend aluminum poles. I have done it but I use 7000 series aluminum alloy pole sections which are strong but brittle and will only accept so much of a pre-bend before they snap. I prefer to use pre-bent angled connections. There are many pole connectors available.
 

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If you end up with short sections of pole pieces left over you can make a whistle (in this case a slide whistle) and a sewing kit. Best sewing kit I’ve come up with. I didn’t measure the waxed sail twine but judging by arm lengths it’s about 18’. I have lots of tubing and sail twine if anyone is interested I’ll share.
Jim

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If you end up with short sections of pole pieces left over you can make a whistle (in this case a slide whistle) and a sewing kit. Best sewing kit I’ve come up with. I didn’t measure the waxed sail twine but judging by arm lengths it’s about 18’. I have lots of tubing and sail twine if anyone is interested I’ll share.
Jim

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Jim, thanks for the ideas. I throw away cut off pole sections of various diameters all the time. I keep a few scrap pieces around for various projects like the handle supports on my bear canister straps.

John
 

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