Here's another take on carbon pole tips.
You basically turn the end of the spreader in to an archer's nock. This plan will address the concerns of a nock - splitting under load and damaging the ends if you drop them.
First, cut a 1/4" long segment of insert and glue it 1/2" from the end of the tube (this makes a 1/2" deep nock). Next, glue a carbon washer over the end -
https://www.amazon.com/Carbon-Fiber-...01IITBQHU?th=1.
Then cut a notch in to the end of the pole, slicing the washer along the way, stopping just at the outer edge of the insert. This is where your suspension cord will rest, like the string of an archer's bow. Adjust the width of the cut to suit the diameter of your cord. You can start by first drilling a hole across the tube to set the depth of the nock if you like.
Tie a big stopper knot in your suspension where it will sit inside the pole end to keep the pole from sliding on the cord. It'll pass through the middle of the washer when you assemble the spreader, so this will act a bit like a keeper.
That 16mmX0.5mm tubing weighs 0.9g/in and the insert tubing about twice that. For a half inch deep nock:
0.9g/in * 0.5in = 0.45g
1.8g/in * 0.25in = 0.45g
washer = 0.36g
Total: 1.26g
The material removed with the cut/drill will balance some of the weight of the epoxy and the stopper knots also weigh more than nothing. Pending epoxy, you're around 5g for the set, or 0.18oz.
For a pair of 36" spreaders w/ 5" insert, this will put you at 3.1oz - well under 3.5oz w/ epoxy.
Fingers crossed that thin wall tubing is up to the task!
For reference, the density of epoxy resin is in the range of .001 - .0015 g / mm3. A bead around the inside if the tube 1mm^2 in cross section would weight ~0.06g.
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