I'd rather not get into a debate of what it's for so if you recognize the part let's just refer to it as a broomstick.
I need to make this lighter.
I need the threads on the right. My thought was cut the aluminum tube, lathe it down so I have an overlapping press fit to glue. Sound good? Also any concerns cutting carbon fiber? Same as fiberglass or will I regret it?
Cutting is about the same as fiberglass, including the itchyness from the loose fibers you'll get everywhere. If you want a good bond you're going to need to figure out how thick your glue wants to be (not an interference fit, probably like .005" or something and then a press fit shoulder to keep it centered) and make sure you use something nice and abrasive to rough up the carbon surface, clean it super well to remove mold release, and ideally etch the aluminum (can probably get away with just roughing and cleaning super well here too). This is more or less how the tie rod and pull rod below were made:
So this process is (very basically) bonding a premade CF tube to an aluminum tube?
In reply to ¯\_(ツ)_/¯ :
Is that a FSAE car? Looks a hell of a lot like what Lehigh made the last time I was competing...
Back when I was in fsae (2006) we did carbon push rods and tie rods on the suspension. Hysol was the adhesive, good stuff. Expensive but worth it. Should be data available about clearances required.
In reply to sobe_death :
¯\_(ツ)_/¯ went to Lehigh, and was part of their FASE team. 
In reply to sobe_death :
Yep, you got the school right and everything! I believe we used a Hysol product as well, but as noted it isn't cheap. I would bet you can get alarmingly close with stuff you can find at Tractor Supply and Harbor Freight.
paranoid_android said:So this process is (very basically) bonding a premade CF tube to an aluminum tube?
What I want to do yes. I also want to extend the tube and attach a CF handle to the left side of the broom.
In reply to ¯\_(ツ)_/¯ :
Thanks. Looks like even I can do it.
There are typically woven carbon scraps leftover from serial production fpr cents on the dollar via craigs and fleabay. Just a side note. Seems like a fair amount of direct experience here. If possible I'd trim and fit before resin. Carbon loses drastic properties when scratched or etched due to having a factorial smaller aspect ratio.
In reply to 84FSP :
I think version one of this can be made with a premade tube, rod, and block. At least I hope so.
Stampie said:paranoid_android said:So this process is (very basically) bonding a premade CF tube to an aluminum tube?
What I want to do yes. I also want to extend the tube and attach a CF handle to the left side of the broom.
I’ll be curious to hear how this turns out. For the next time I need to make a broom.
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