Contents

Obtaining a replacement pole
What should the replacement pole be made out of?
Preparing the replacement pole
Fitting the replacement pole

Obtaining a replacement pole

Having successfully extracted the pole the first thing to do is to measure it and use the dimensions when ordering a replacement pole.

The measurements of Sospiri's pole were:

• External diameter 27 mm
• Thickness of tube walls 3 mm
• Length of tube 59"

What should the replacement pole be made out of?

The two main options were either Bronze or Stainless Steel. Whichever is chosen depends on cost and availability. Honnor Marine fit a splendid curved bronze pole on their Luggers and offer a service of fitting one to an original boat, but do not sell the parts separately.

Since writing the above I have been able to source a suitable phosphor bronze rod of diameter 1 1/8 inches from Classic Marine. Cost including UK tax and shipping is in the order of 164 UK pounds. Visit their website to find out current costs and to make enquiries.

In the end I decided to investigate the stainless steel option. A. Fletcher Marine, the company that had previously supplied me with a customised stainless steel bolt, also supplied stainless steel tubing primarily for use on yachts. They were extremely helpful and gave me a good quote for supplying marine grade (316) stainless steel tube 60" long. 26.67 mm in diameter and with a wall thickness of 2.11 mm.

However, A. Fletcher Marine ceased trading in 2013, so now I would investigate either Classic Marine or Seascrew for sourcing the stainless steel tubing.

Preparing the replacement pole

The first step was to use the measured length of the old tube to mark on the new tube the exact length required. A soft (HB) pencil was used for making a mark on the tube. The easiest way to cut it is to clamp it in a horizontal position - a Black and Decker 'Workmate' is ideal for this - and then cut it using a hacksaw. The cut end of the tube was then smoothed off using a sanding block and grade 120 Aluminium Oxide paper.

Next the fixing holes for the stainless steel self tapping screws were marked and drilled. The pole was clamped in position and, using the original pole as a guide, the new holes were drilled to a diameter of 4 mm at 13 mm from one end and 11 mm from the other end. The holes must as far as possible line up horizontally on the pole. A steel tape and pencil were used to mark the position of each hole. A centrepunch was used to indent the surface of the tube at the position of each mark to ensure that the drill would not slip out of position whilst making the holes. An electric drill was used to make a pilot hole of 2 mm diameter which was then followed by drilling to the final diameter of 4 mm.

Fitting the replacement pole

This is essentially a re-run of extracting the old pole.