A fall resulted in the breaking of the lower section of an adjustable CF trekking pole at the junction of the two sections.
We considered an external splint – using a section of tubing for tent pole repairs.
We considered an internal splint – a headless Easton stake with tape "arbors" to keep it centered.
Neither would allow for subsequent adjustability.
After looking at the pieces, and the length required for functionality, we concluded that IF we could cleanly cut the CF, we could 1) remove the shattered end to restore integrity, and then 2) cut the tip-end shaft such that it would then fit inside the refurbished Lower.
We also had to overcome the problem of removing the shattered Lower from the upper. There were only shards sticking out, and it became clear in trying to twist them unsupported they would not convey enough torque to loosen the expansion plug.
After a few minutes of staring at the parts I realized that a pole tip would fit inside the fractured Lower extending from the Upper. A very careful press and twist ("lefty-loosey", practiced a couple of times to make sure of things) resulted in the lower section coming free. We got lucky.
Next was how to cut carbon fiber. What we needed was a 32 tooth hacksaw blade. We had a Swiss Army Knife saw blade, but I knew it would shred the CF. We considered a metal nail file, but thought it would take too much effort and time. I felt a "typical" knife blade was to blunt. What next came to mind was the $1.99 DermaSafe razor/knife. Sharp and Thin. Surely it was no match for industrial strength carbon fiber? But nothing ventured, nothing gained.
I wrapped plastic micropore tape at the cut line as a guide and to control splintering, and slowly scribed in a cut. And kept going around and around. And in less than 5 minutes, had a perfect, clean end! Who wudda thunk?
Next I eye-balled the tip end, trying to guess how high to cut the taper so it would fit snuggly inside the refurbished end of the Lower, but not to big, requiring a third reducing cut. We only had 2 DermaSafes, and we assumed that they weren't good for many cuts.
I got close. I added a couple of wraps of tape to build up the tip shaft for a snug fit into the Lower, and to reduce any stresses induced by the abrupt edge. The end of the Lower centered and settled on the shoulder of the tip. It was good.
Last, we cut several ¼" x 2" sections of LeukoTape (a static, non-stretching cloth tape), put two wraps around the end of the Lower to keep it from expanding, and then bound the tip into the Lower. I was confident the lower could take the pressure of support against the tip shoulder, but I was afraid the tip could get pulled off in muck, or in a crack, and become lost forever. (BTW, the DermaSafe was done. I could not begin to cut the LeukoTape with it.)
Here is a comparison shot of the intact and the refurbished lower sections.
After 8 more days of rock, talus, water crossings, and scree, the tip was still in place, as hoped.
