How to Build a Pole With Aluminum Tubing
Aluminum tubing is similar to metal tubing. It comes in various thicknesses and lengths, depending on what application you are using it for. While aluminum tubing is most often used for structures, frames and other outdoor applications, it can also be connected together to form a large pole. Poles may be used to hold flags or to hang other objects from. Aluminum tubing does not come in a length large enough for some poles, but it can be put together to form a big pole. Does this Spark an idea?
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Things You'll Need
- Tape measure
- Black marker
- Hacksaw
- Metal file
- Rubber mallet
- Propane torch
- Gloves
- Safety goggles
Instructions
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1
Determine how long the pole you are making will need to be for your particular application. Gather up enough aluminum tubing to make a pole of that length and lay everything out on the ground.
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2
Measure and mark any piece to be be cut to size, if necessary, with a tape measure and black marker. Cut the piece with a hacksaw. Move the hacksaw back and forth over the mark on the tubing until it is cut. File down the cut piece with a metal file. Rub any leftover scraps of metal away from the edge.
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3
Push the aluminum joints into the ends of the tubing by hand and hammer them down in place with a rubber mallet. These joints are made specific for each size of tubing and help connect the pieces together. Repeat the process for all of the aluminum tubing and connect everything together to form the pole.
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4
Turn on a propane torch and hold it 4 inches from the surface of the tubing. Position it where the first joint connects the two pieces of tubing and turn on the torch. Move the flame back and forth over the area for about 20 seconds, until the pipes have welded together.
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Move down to the next joint and repeat the same process. Continue in the same manner until you have welded all of the pipes together with the propane torch. Turn off the torch and let the aluminum tubing cool down before attempting to touch it.
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Tips & Warnings
Always wear gloves and safety goggles when you are working with a propane torch.
