I registered for my first GORUCK event, Rucking University class 010, two and a half months before the start of the event. When I noticed that nobody had yet volunteered to bring a flag or flag pole to the event, I decided that I wanted to try my hand at designing and assembling a flag pole for the event and posted that I would be responsible for bringing these items. I did some research on AAR blog posts, looked at event pictures, and checked out posts on the GORUCK subreddit to get inspiration on how to make what I hoped to be a solid GORUCK challenge flag pole. Here are checkboxes that I wanted this flag pole to hit:
- Follow rule #1 to a T
- Securely accommodate a standard 3’x5’ US Flag
Like Cadre Hot Mike said to the Berkeley MLK 2017 Light Challenge class...
If the flag hits the deck, this event turns into Selection and I'll beat all of you all down until you all quit.
- Be at least 8 ft. long
According to a report on the GORUCK subreddit, Cadre Glenn Wells Flash requires flag poles for his challenges to be 8 feet in length minimum. - Be solid and sturdy in construction
Many challenge flag poles use PVC but interestingly I read of somebody using EMT conduit. I compared the materials in weight and an 8 foot length of 3/4” EMT conduit is ~1.7 lb. heavier than PVC of the same dimensions. However, when I was in the store, it was clear to me that I wanted EMT just because it feels so much sturdier in the hand. - Best in class grip for comfort and security of the flag
- Easier to secure in the ground safely
- Operate silently
GORUCK rucks have paracord and shrink tube zipper pulls instead of the usual metal ones. This allows the zippers to be silent instead of jingling like Santa’s sleigh when you walk. I wanted to the flag pole to fall under the same principles. No metal on metal clanging.
After a number of trips to hardware stores and making friends at my local metal working shop, here’s what I came up with:
Finished product.
Materials:
- 1x 10’ length of 3/4” EMT conduit
found at almost any large home improvement store - 2x (4x recommended) Black Plastic S-Biner
- 2x (4x recommended) 1/4” x2 in. (get 2 1/4” if you can) eyelet screws with nuts
- 1x (2x recommended) roll Howies hockey tape
- 1x pack of 7/8” black rubber furniture tips
- 1x (2x recommended) 1” PVC cap
- 1x (2x recommended) 3/4” PVC coupling
- 1x (2x recommended) mini bungee cord
Tools:
- Needle-nose pliers with wire stripper (if you have two, have two handy)
- Drill with small drill bit 1/16" drill bit
- Your friendly local metal-working shop expert OR
- Drill and 1/4" bit capable of drilling through EMT conduit
- Saw capable of cutting through EMT conduit at an angle
Optional:
- GORUCK Wire Dopp or Tough Clutch
- Blank or “My Name is” Patch
- 1x pack of zip ties
Construction Directions:
1. Take your EMT conduit and from one end measure 2” down the conduit and mark it with a dot, then measure 3’ down from that point and mark that point with another dot. Drill two 1/4" holes straight through the conduit on the dots. These holes should be aligned as they will be used to fasten the hardware that will secure your flag to the flag pole.
NOT TO SCALE!!! :)
2. On the other end of the conduit, from the end measure down 2’ and mark that point with a line. Then go down 4” from that mark and mark that point with another dot. Drill a 1/4" hole on that mark, then cut the conduit at an angle from the line marker you made so you will be left with a 3” spike at the end.
NOT TO SCALE!!! :)
3. Take your eyelet screws and run them through the two holes you drilled in step 1. Make sure the eyelets are on the same side of the conduit and use your needle-nose pliers to securely fasten them so that the eyelets run parallel to the conduit.
Fancy photo angle just showing how to arrange the eyelet screws.
4. Put one of your furniture tips on the end of the conduit that is 2” inches from one of the eyelet screws.
Look at that craptacular photography!
5. Take your PVC coupling and mark 1/2” down from one of the openings and drill a 1/16" hole into it.
Cut 1/2" from an opening on your PVC coupling.
6. Secure the PVC cap onto the end of the PVC coupling opposite from the end that you drilled in step 5. This is your stake guard.
Completed stake guard, holes are on the sides.
7. Take one of your mini bungee cords and push the hooks next to each other exposing one of the ends of the bungee cords that is crimped with a metal clip. This is called a hog ring. Using your needle-nose pliers remove the hog ring. This is easier if you use two pairs of pliers at the same time. SAVE THE HOG RING!
8. Remove one of the bungee hooks and run the cord through the hole you drilled in step 2.
Bungee in the hole!
9. Replace the bungee hook back onto the cord and re-crimp the cord using your needle-nose pliers so the bungee hook will stay attached to the cord.
10. Using your pliers, open the hooks on the bungee cord and push the hooks into the holes you drilled into your PVC stake guard. Then use your pliers to close the hooks as much as possible on the inside of the PVC guard. You can know secure your stake guard onto the stake of your flag pole! Safety 1st!
NOTE: If it feels like the bungee isn't pulling your guard enough to keep it snug, just take the guard off, remove the bungee hook from the guard, remove the hook from the bungee, and trim the bungee enough to keep it snug.
Completed stake guard, attached with the bungee hooks.
Completed stake guard
11. Take your hockey stick tape to create a knob and grip that starts 10" from the bottom eyelet and runs down 36". You could just run the tape around the EMT like a plain Jane or dull Dave, but then you’d be forgetting rule #1! For best results, roll out a knob with finger grips along the length of the grip. Here’s a great tutorial on how to do this on YouTube (please note he's only doing a ~6" grip, you're going for 36"!):
Check out that grip!
12. Almost done! Take your S-Biners and put one on each eyelet.
S-Biners attached, don't mind that shady looking shadow...
13. Last and very important step! Attach Old Glory onto the vacant clips on the S-Biner and take a picture of you and your amazing flag pole!
14. OPTIONAL:
Take your pliers, extra hardware, and zip ties and put them in your wire dopp or tough clutch. Now you have a nifty Flag Pole Repair Kit, just be sure to use a patch to mark it! Remember: 2 is 1 and 1 is none!
Two is one and one is none.
Some of the features of this pole:
- Hockey tape grip and knob will help you carry the flag comfortably and securely!
- S-biners allow for quick, easy, and secure attachment and detachment of flag
- Plastic s-biners reduce the amount of noise created when the s-biners hit the flag pole.
- Black furniture cap on the top help with rule #1.
- Stake end of flag will help secure flag into the ground. ***THIS IS A WAY OF *HELPING* TO SECURE YOUR FLAG INTO THE GROUND, YOU SHOULD STILL STACK RUCKS AROUND TO INSURE YOUR FLAG DOES NOT HIT THE DECK***
- Stake guard will stop GRTs from stabbing either themselves or one another with the stake-end of the flag pole.
Objectives for Challenge Flag Pole Mark 2
- Plastic S-biners are pretty quiet, but not quiet enough. I want silence.
- When using the stake, dirt gets stuck into the end of the pole. This needs some re-thinking.
- Stake guard design needs refinement, feels clunky.
- Pole needs to be collapsible, want to figure out a way to make it easier to transport to and from events.
BIG THANKS
to the crew over at Bob McGee’s Machining Company Inc. who gave me a really deep discount on the drilling and cutting of my EMT conduit. If you are in NorCal and want help making your challenge flag pole or need some metalwork done, these guys are great.