Super Jet Step by step cutting my sj pole

[Peter123]

Well, with supervision by Smoofers, I cut my pole 3.5" this last Friday (even though we were supposed to go riding instead).

Here is my step by step summation.

First, I measured the distance. I wanted to take it down 3.5" from stock. There was about 1" inside bracket, so I measured and marked 2.5" back from it.





I then ran tape around pole.



I used a Dremel to cut through the fiberglass.



Next, I used a hand saw to cut through the foam. After that a quick sand job to the end.



Then I used a drill press to remove the rivet heads.



At that point, I used a screwdrive to pull out the foam from the mounting bracket. A punch and a hammer was used to pop out the headless rivets.



Then I used the Dremel to remove the dried up resin and crap from inside the mounting bracket and the metal strips. I also taped the pole 1" from the end that will go into the mounting braket followed by sanding it.



A razor was then used to score the end of the pole for better resin grip as well as remove a small sliver of foam to make room for the metal strips (keeping the edge of the pole from bowing out and being more difficult to get back in the bracket).



A quick rub down with acetone to clean all surfaces.

 

[Peter123]

Next (and lacking a couple of photos, sorry), the metal strips were put back into the pole where the sliver of foam was removed. Resin was liberally applied to the end of the pole and inside the bracket. The bracket was manually pressed onto the pole by hand. Then I drilled through the existing bracket holes, pole and metal strips. Then I put a little resin on the rivets and rivetted the pole and bracket.



Then I used a little acetone to wipe off excessive Resin. And the pole was done.



Well, then you have to clean up the "work bench" for beer pong.



Next Sunday, I hope, I'll be installing the hazard bracket to my spuare and mounting the pole.

 

[smoofers]

Good step by step thread!

 

[ryan]

no glue ? to hold the pole in the bracket? that will be lose in a week.

 

[brett]

i like to use epoxy but ive used 5200 and it worked great

 

[kiddioo]

no glue ? to hold the pole in the bracket? that will be lose in a week.

Resin was liberally applied to the end of the pole and inside the bracket. The bracket was manually pressed onto the pole by hand. Then I drilled through the existing bracket holes, pole and metal strips. Then I put a little resin on the rivets and rivetted the pole and bracket.

.

 

[Shonuff]

Nice job, excellent writeup.

 

[Tyler Zane]

you give me confidence to chop mine up today. too bad its gonna be a warm sunny day, i guess ill just have to ride. darn-it. nice write up