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How to make a fire staff.

cheap and short-lived drill
6ft aluminum staff washers
First you need a drill,
aluminum pipe (1"x6', $9),
two bolts (#8, 2.5") and nuts,
scissors
washers duct tape - 3M!
scissors,
two washers,
duct tape,
nomex -3" X .125" x 50' duct tape start rolled nomex
and nomex (3"x.125"x50'). Anchor the nomex.
Roll thirteen layers.
rolled and measured drill that thing secret technique
1.5" thick
Drilling (11/64" bit), see note!
Super secret method...
secret nut technique screwed trim the nomex
for holding the nut.
Final assembly.
Just a little off the top please.
final staff
The finished product!
staff in operation

Nuts: I used nuts with the nylon inserts. I hope they won't end up melting into uselessness. I'll keep you posted on that one.

Nomex: I found this at McMaster-Carr supply company (http://www.mcmaster.com/), head to the site and search for 'nomex aramid strip'. I bought part number 8796K34; 3" width, .125" thick,  50' for $39. I used about 12' total for this staff. It doesn't last as long as the kevlar-reinforced material, but it costs much less.

Tightening the roll: For a 6' staff, aim for a thickness of 1.5". After getting thirteen layers, I held the outside of the roll and rotated the staff a couple of turns to tighten up the fabric. For smaller staffs (4') you will want to budget eight and a half feet (four per side) to get a thickness of 1". Don't use more, the flame will be too large to handle safely.

Drilling: I actually put the drill in reverse (counter-clockwise) at first! If you just start drilling, the fabric will just wrap itself around the bit. So, put the drill in reverse and press down hard. Drill slowly for 30 seconds. This will start the hole. Now put the drill in forward, hold the fabric as shown, and drill SLOWLY. It should start to drill into the fabric. You should be aiming for the center of the pole. Stop after drilling into ONE side of the pole.


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