How to Reinforce an Aluminum Ladder
Aluminum ladders are preferred by many craftsmen and homeowners because they're affordable, lightweight and strong. But most aluminum ladders still have a great opportunity for a design improvement; the majority of them have hollow rungs that, despite the strength and integrity of aluminum, can bend or even break with enough time and use. Reinforcing these rungs can be done cheaply and quickly, and the additional strength can add many years to the life of your ladder. Does this Spark an idea?
Instructions
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1
Verify that your ladder has hollow rungs. Most aluminum ladders do, and the ends of the rungs are left open on both sides of the ladder. A few models may have rubber or plastic plugs filling these holes. If yours does, remove them.
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Measure the diameter of the holes and write that figure down. Then measure the length of the rungs and write that figure down, too.
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Purchase wooden dowels that are approximately the same diameter as the rungs and at least as long as the rungs. Buy one dowel for each rung. If you can't find a diameter that is just right but you can find one that is slightly larger and another that is slightly smaller, go with the smaller one.
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Measure each dowel and mark them at the same length as the rungs. Use a hand saw to cut each dowel down to size.
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Lay the ladder on its side on a flat, sturdy surface or on the ground. Position it so that a side of the ladder with open ends on the rungs is facing up. Stick a cut dowel into one of the rung holes and gently tamp it into place with a rubber mallet.
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Use the rubber mallet to tamp the remaining dowels into each of the remaining holes. When they're all filled, each rung will be far stronger than before and the added weight will be trivial.
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Tips & Warnings
Don't try to force a dowel that is too large in diameter into one of the rungs. You could wind up denting or damaging the ladder.
