I was tasked with making a pole for an MLD super-mid after the supplied one failed. The result is something of a whopper but I believe mission accomplished. For those who don't know, the super-mid is a 4 person pyramid shelter that stands nearly 2m high, so there's a massive loading potential.

Standard pole was 14mm OD roll wrapped carbon. New one is 20mm OD woven carbon. Standard spigots were 12mm OD pultruded carbon with a 1mm wall. New ones are 18mm OD woven carbon sleeved, so they now have a 2mm wall.

Total weight is 230g which sounds a lot but given the size and potential strength is quite reasonable. Here it is next to a standard sized pole.

What’s the process for making a carbon pole?

What’s the process for making a carbon pole?

It kind of depends but generally ...

1/ Decide on diameter and wall thickness.
2/ Decide on folded length and cut required number of sections and grind ends square.
3/ Decide on the type of spigots - internal, external, solid or a combination.
4/ Cut spigots to length.
5/ Measure clearance / fir between sections and spigots - you may now need to grind the inside of either spigots (if they're external or inner ID of sections to achieve desired fit.
6/ Rough all parts to be bonded then thoroughly clean and leave to dry.
7/ Once dry check fit one last time and bond everything together. Clean each part as you go along as the resin begins to harden quite quickly.
8/ Leave to cure overnight. Check fit / length once again and adjust if required.
9/ If aluminium tips are to be fitted, grind appropriate sections square (you've fitted a sleeve inside the section to hold the tip when you fitted the spigots).
10/ Give everything a polish and then assemble.

There's more work in something like the one above as the spigots themselves are also sleeved, so you're kind of doing the job twice.

Bearbonesnorm wrote: ↑Thu Aug 18, 2022 6:01 pm Standard pole was 14mm OD roll wrapped carbon. New one is 20mm OD woven carbon. Standard spigots were 12mm OD pultruded carbon with a 1mm wall. New ones are 18mm OD woven carbon sleeved, so they now have a 2mm wall.

Total weight is 230g which sounds a lot but given the size and potential strength is quite reasonable. Here it is next to a standard sized pole.

Mhhh... looks lovely

There will be a time... when I come begging for one too
My girlfriend and I often use a ca. 175 mm tall mid. Some day...