Originally Posted by Vincent
Hi. Just in case somebody out there has broken an older HPL carbon race boom, but still has the carbon rear end in good shape, I'm interested in buying the rear end. Specifically I'm looking for the older "Race" rear end with the squared off tail and 4 pulleys sandwiched into the squared off carbon tail piece. This if before they did the monocoque tail. My boom is a 2004(?) blue "Hybrid Carbon Race 220". The tail has 60 cm of adjustment range. Thanks!
if you can't find a rear end, and if the extension tubes on your rear end are still OK (i.e, the break occured in the actual tail piece, so you can cut the tube at the joint to the old broken tail piece and salvage them, albeit at a wee bit shorter length), you can fashion your own tail end pretty easily with a bunch of carbon tape and something to use as a spacer (a block of marine-grade plywood should work great). Then you just bolt a few blocks to that new end-piece and you're good to go.
The way to set it up is to create a block of wood approximately 4" long, 1" thick, and 2" deep. Sand the wood to create a groove that nestles against the tubes on the side. Set the boom up on a work table and super-glue the block of wood to the tubes. Then start wrapping the whole contraption with 3 or 4 inch-wide carbon tape (wet that down with epoxy first on a sheet of plastic, then roll the wetted carbon with your hands wearing gloves, then do the wrapping). You'll want at least four or five layers of carbon at the joints, and you'll want the whole thing pretty tightly wrapped. Then wrap it in peelply, and then finish the job with a very tight wrap of electrical tape (poor man's vacuum bag). Cure overnight, than peel off the tape and peel play, mount your blocks, and when anybody raises an eyebrow, just explain to them how the old tail piece was just too wimpy and low performance for you.
You could even make the tail piece wider this way (just use a 6" or maybe even 8" long block of plywood) but for a 220+ boom, that's probably going to be less crucial than for a really long one.
I've seen a couple booms salvaged that way, and it seems to work pretty well.