How to Make a Pole Climber

Measure a strip of 1/4-by-1-inch aluminum bar stock 20 inches in length. Use a power hacksaw to make the cut.

Place the aluminum bar in a steel vise with 6 inches extending above the jaws. Use a hammer to pound the extension into a right angle.

Release the piece of aluminum from the vise and hold the 6-inch flange over the end of the vise and pound a progressive 1-inch right angle in the end of the flange.

Release and move the aluminum piece in the vise until the 1-inch flange is isolated. Drill a 1/2-inch hole through the center of the 1-inch flange. Use a reciprocating saw to cut a 1/2-by 3/4-inch slot in the flange. The 3/4-inch dimension should be at a right angle to the long axis of the J-shaped piece of aluminum.

Stand the piece of aluminum up vertically like a letter "J." Measure, mark and drill a pair of 3/8-inch holes, 1 inch apart, in the long shaft of the piece, 4 inches from the bottom.

Measure, mark and cut another piece of 1/4-by-1-inch aluminum bar stock 3 inches long. Place it in the vise and bend it at its midpoint to a slight, 20-degree angle. Reposition the piece in the vise with one of the flanges pointing away from the front. Measure and drill two 3/8-inch holes, 1 inch apart, through the protruding end of the piece. Use a heavy steel file to sharpen the opposite end into a sharp point.

Use 3/8-by-1 1/4-inch steel machine bolts to attach the spur to the climber body. Insert the bolts through the long flange of the climber and though the spur, bolting them on the outside of the "J."

Reposition the climber in the vise with the upper flat surface of the "J" facing front. Drill a 1/2-inch hole thorough the center of the flange, 1 inch down from the top. Use a reciprocating saw to cut a vertical 1/2-by-3/4-inch slot in the flange, for the safety strap.

Repeat this entire process to create an identical twin of the finished product for the other foot.