Procedure for cut-to-length XC poles
The listed length of a cut-to-length pole is with is with the grips installed; the shaft length will of course measure less.
There is no industry standard for the length of a pole grip and the length of the grip above the strap varies widely. The functional length of a pole is not overall but tip to strap. If you are planning to make your new poles the same functional length as an old favorite, keep this in mind.
To build a pole to your desired length the first step is to mark a cut mark on the pole shaft. For your desired pole length, subtract that number from the listed length.
As an example, if the pole kit length is 170cm that will be the finished length with the grips installed as is. If the desired length is 151.8 cm, then subtract this from 170. Ex: 170 – 151.8 = 18.2.
Measure from the open/unfinished end of the pole and make a mark at 18.2cm. This is where you will cut the pole down
Cutting procedure.
Not necessary, but it can be helpful to have a single wrap of tape (preferably masking type) around the cut mark. Carbon fibers are very brittle, and this can help reduce splintering.
Use a very fine tooth saw, best is a hacksaw. Use the saw to make a light score cut all the way around. Now make the cut.
Remove the tape and use a fine mill file or sandpaper to round off/smooth out the edge.
Glueing.
The biggest mistake (but easy to reverse) is to apply the hot melt glue and apply the grip without making sure the grip and basket are aligned! It can help to use a marker pen or grease pencil to make a vertical marking line on the shaft to help align with the basket.
Use a heat source to warm the shaft and the interior grip (careful! Just warm, don’t risk melting the grip plastic).
The best heat source is a heat gun. Hair driers are a maybe. A blowtorch or candle can be used but be very cautious. Next, heat up the glue stick until the end starts to melt.
Apply the melted glue to the pole shaft (and if necessary, do some more heating), others like to smear a drop into the opening of the grip. You need surprisingly little melted glue!
Without delay squeeze the grip onto the shaft being aware of alignment!
If a do-over is needed, it is often better to place the grip end of the pole in a pot of boiling water instead of using a heat gun as a heat gun used too aggressively can delaminate the cork on grips using a cork lamination.