I'm thinking in terms of a Forecast SP720 which is rated 2-6lb. 3/8" AL tubing with .016 walls will be a good fit as long as it's strong enough. My thought is to us run the tubing the length of a TN handle then glue the blank (appropriately shimmed) into the end. It should make for a 6'9" or 6'10" UL that is lighter than my IP840.

In aluminum, that would be considered a very thin walled tube. However, for such a light rod and with the use of very light line, you may get by with it. What is the diameter you'll be using?

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3/8" OD aluminum, which makes the ID .343". I could also step up to .035" wall thickness and go with a larger OD tubing, but if unnecessary I'll save the weight and stay with the 3/8". While I'm at it - where does AL tubing tend to fail on light rods? Does it split out at the end or bend?

It doesn't tend to split - it folds up. Very thin walled tubing could split at the junction with the blank if you put enough stress on that point. But even that can be somewhat negated by a reinforcement wrap over the junction area just like what you do on ferrules.

That's a very light blank and you may be okay. I'd opt for the 1/2 inch diameter variety over just moving to thicker walls if you feel it may be suspect.

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Marty,
Aluminum will work, but why use it.
Just pick up an old or new blank and use a section of blank on the "outside" of the blank to be extended.
Readily available with no issues on strength.

Just trim the blank that you are going to use so that it is a nice tight fit on the outside of the blank to be extended. Just insure that you have at least a 4 inch overlap and you will be good to go.

With a Tennessee handle, there is no issue with respect to reaming the cork rings or cork grip to fit both the original blank as well as the extension.

If you don't happen to have any spare blank stock around, just go over to your local good will store and pick up a dozen rods for 50 cents each. This will give you a nice variety of spare graphite material.

Most blanks need a touch of weight near the butt of the rod, so a bit more weight in the form of the graphite extension will work to your advantage.

Good luck
Roger

Marty,

If you decide to use aluminum tubing, make sure that it is tempered aluminum, such as 6061-T6. - Do not use tubing that is not tempered, such as you typically get at the local hardware store, because it is too soft and will bend.

Been there AND DONE THAT!, and I now have an unwanted bent butt rod.

Rena