Broken Extension-Pole Repair

Digging around the neighborhood today (t'was bulk-pickup day), we found a badass extension pole. Why was it in the junk pile? The fiberglass housing/outer section was broken. Where others see junk, I see junkertunty!

Fiberglass Repair Kit,

1-1/4 Inch Slide Repair Coupling

Broken Extendo-Pole

Solvents for Clean-up

Paintbrush

Digital Scale

Disposable Mixing Cup

Sandpaper (medium grit)

Go out on your local bulk-pickup day, and find a broken extension pole. Or, alternatively, you can buy a new extension pole, and break the fiberglass sheath through which the inner extensions slide. This latter option will cost you close to 100 bucks, and would be (let's face it) quite the foolish way to learn some repair skills - but if you should happen to break one on accident, Mazel Tov! We can get started ...

If you should happen to frequent a Mom-'n-Pop hardware store, kudos to you. The rest of us heartless sellouts will be hitting Home Depot, Lowes, Amazon, or (if we're really desperate) Ace Hardware. There you should be able to find:

1) A Fiberglass Repair Kit (I used one by "Bondo" which includes both of the two-part epoxy ingredients, as well as a sheet of fiberglass wrap).

2) Solvent (I used paint-thinner and paint stripper, but, should you be more industrious than I, perhaps the "perfect solvent" for this application exists: post in comments). Beware, paint-stripper is quite caustic, so be careful with it, and, when you inevitably spill a couple drops on your leg, you'll know pretty-damn quick! Wash that napalm off with the quickness.

3) Paintbrush (no need to go fancy, just make sure it'll stand-up to whatever solvents you use). This may be a one-hitter-quitter, so don't pay so much that it'll hurt if you've gotta throw it away after use.

4) Sandpaper

Secure your workpiece (fancy shop-terminology for broken pole) in your bench vise. If you've not got one, a few clamps'll do the trick. Place a sheet of cardboard under the section you'll be mending. Use some medium-grit sandpaper to clean-off any of the unwanted fiberglass from around the break. Finally, clean all the area around the break with rubbing alcohol, etc.

You want this to wrap fully around your workpiece a couple times over. It should also extend a good couple inches to each side of the break. You want to have it cut beforehand because, once you mix the two-part repair solution, the clock is ticking on how long it'll be workable.

It should come with both a bottle of Fiberglass Resin, and a small tube of Liquid Hardener. Mix the two thoroughly as per the directions in a disposable cup.

First, slide the repair coupling over the pole, well away from the section to be mended, so that it'll be easy to affix in place once the time comes. Make sure you've got a roll of paper towels and some high-strength rubbing alcohol ready-at-hand. Keep the pole tight enough in the vise for it to be secure, but loose enough that you can rotate it. Slather a generous helping of the now-mixed repair solution over the section to be repaired, and do just-over one full wrap of the fiberglass cloth. At this point, pulling the loose end of the cloth should make it nice and snug, if there's at least a good quarter-turn of overlap. Make sure it's as even as you can get, with none of the wrapping bulging out. Now you can take your paintbrush and slap another generous coat over your first layer, adding a second layer the same way. Place the end of the cloth under the workpiece at first, to let it's weight hold it snug. After you've got as many layers as desired (I used only two), keep your shop fan on the workpiece as it dries, and keep the garage door open to let some ventilation disperse whatever is now in the air. Set a timer for an hour and a half.

After about an hour and a half, with the repair epoxy still tacky, slide the inner pole in and out a a bit a couple times: this'll make sure that you don't have it seizing in place. Now repeat the previous steps, adding another couple of layers of fiberglass repair cloth. Once this is done, slide the repair coupling directly over the break. It ought to be snug, but not so tight that it disturbs the wrapping underneath while moving into place.

Let that sumbitch dry, as per instructions. Assuming all went to plan, your extendo-pole is better-than-new: it's now got a new grip halfway up! Mazel-tov! Now go get yourself some attachments for your better-than-new extension pole, Mr. (or Mrs.) Fixit! And, finally, take the 60-odd bucks you've just saved, and buy a gift for dear-ole' Mom ... and give her a call, why don't-ya? You never call!