Originally Posted by David Ingram
I need to repair my Battlestick, what's the best way to do this?

I was thinking about buying a roll of 1 inch Carbon Fiber Tape and some kind of jig to keep the stick straight. Is there a better way to do this repair?


You need at least 2" tape...probably 3". You can also cut some fabric from a roll.

I've fixed several of these...I've fixed them without the jig before by temporarily epoxying the ends together and letting that cure on flat ground before starting the reinforcement repair. The jig I have has two pieces of angle iron aligned and bolted to the upper ends of a "U" shaped piece of plywood. The angle iron extend past the wood uprights so I can place two winds of tape on each broken piece to attach them firmly to the angle iron. Once one of these are done, you can do the following:


Before doing anything, rough sand the outside areas where the repair carbon will wrap with 80 or 100 grit. Lay some poly plastic on a flat surface large enough to support the entire stick (obviously, the plastic only needs to be under the repair). If you can lay it out in the sun, you will get a faster cure.

Make 3 to 4 wraps around the tubing with epoxy wetted carbon (tape or cut fabric) ... more is fine, you can sand them away. Start above the repair and start wrapping electrical tape around the stick over the repair into the clean area below the repair and back up again. You should have two wraps of tape around the stick - get it tight! With a sharpened nail, poke holes through the tape into the carbon...it will now bleed out excess epoxy and compress the carbon fibers - and stabilize the joint (I have done this without any thing aligning the two pieces before with good result). You can wrap it with a paper towel if you are worried about epoxy getting up or down the stick. Lay it on the ground on the poly. If you didn't previously stabilize the joint, roll the stick back and forth on the ground making slight alignment adjustments until it's roll shows that it is straight and true. Let it cure.

Unwrap tape (removes very cleanly once the epoxy is cured). Sand to 180 grit to clean up tape marks. Shoot some Krylon clear enamel on it...and now you have a repair that is also a decorative feature.


Jake Kohl