Shortening an Aluminum SN Pole

[SJ/XPBri]

I've got a stock length aluminum hand pole on my square nose. This thing has to be shorter. I want to cut the pole and take out at least 3". Where should I take the 3" out? The easiest place as far as welding it, would be the middle boxed section. I was also thinking that the top section of the pole where the steering mounts to would be a better choice, because it wouldn't affect how the pole sits on the hood.
Thanks,
Bri

 

[Matt_E]

That will probably mess with your steering cable. The distance between the steering cable clip and the bars needs to stay close to the same, doesn't it?

If you cut 3 inches out of the middle, you will have fitting issues on the hood, but it can be done.

 

[demolition_x]

if you cut in the middle just grind the welds smooth and all should be well.

 

[SJ/XPBri]

Not that this makes a difference, but when I say the "middle" of the pole, I just meant the box section (shortening it like a stock fiberglass pole). MattE- very good point, didn't even think of the mounting points :biggthumpup:
I'll keep ya posted
Bri

BTW- here's the before hacking picture:

 

[Matt_E]

Shortening the box section 3 inches will cause you problems. It brings the top end of the pole closer to the pole channel in the hood. The top section is wider than the box section, so it will not fit in that channel. I know that with a -4 inch pole, we had to cut the hood up to get it to fit.

 

[SJ/XPBri]

Ok I've measured the top portion of the pole. There is enough room to take the 3" out without causing interference with the steering cable mount. This should allow me to chop it, reweld it, and not make any modifications to the hood. Also, the pole will still sit fine in the hood. Obviosly the top portion of the pole flares out so I'll have to fabricate something to fill the gap.
Thanks,
Bri

 

[Sanford]

I've been debating doing this, or even offer it as a swap service.

If you just do a straight cut (in middle) and plain butt-weld it you will compromise the strenght. Unless you don't ride aggressive.

The best way to mod this would be to cut in half, drill 1/2" holes (12) near cut edges and weld 1/4" stock (placed inside the pole) through the holes using rosette type of welds. Then insert one end with the already welded 1/4" stock and weld the other end of the holes (rosette). Now all that is left is to TIG up all the rest (make sure you gring a deep V channel to help the TIG penetration).

 

[Boris]

That sure is a purdy pole.
Why don't you get a RN pole and bracket and sell that shiny pole of yours on ebay ?

Would be a shame to destroy it if things don't work out.

 

[SJ/XPBri]

The welder that is doing this has a masters degree in metallurgy. I'm not touching this with the mig. Sanford good idea for the reinforcement. Boris, don't fear, this will not be a "sacrafice"
Bri