Polycarbonate vs. G10 phenolic.
G-10 fiberglass reinforced phenolic is absolutely amazing stuff. Get yourself a 3" length of that and you can smash cinderblocks without even scratching it. Three problems: 1) expense. The stuff cost $10-$15 per linear foot. 2) machinability. You need carbide or diamond tools to even scratch the stuff and it wears them out real quick. So if you like the rod just as it comes from the manufacturer, no problem, but if you want to round off the ends (avoids cuts and makes a nice rib spreader) and put some knurled grips like I do, you just can't do that kind of thing on a standard mill or lathe. 3) Rigidity. G-10 is used in high voltage power systems where you need something with great structural rigidity but doesn't conduct electricity. When you whap something with G-10 phenolic, it really sends a shock wave up your arm. If Eric Blair/Mare Blair/F-stix/usual suspects network is still in business, they are working on making G-10 phenolic fighting sticks. Last I checked, he wants $150 for a pair.
Polycarbonate is relatively cheap. You can buy a police riot baton, 36"x1.25"diameter with rounded ends and knurled grips for ~$50. If you are comfortable with machining your own or know someone who is, then you can buy your own stock from a local plastic supply merchant and then round off the ends and put your own knurling on. That is what I do. I sell a 33" x 1" diameter clearish polycarbonate stick to my guys for $25. That is about $15 in stock, $10 for me and about $30 in my time and wear and tear on the governments lathe that are not figured in. For the half dozen or so I have made, no big deal. If I had to buy or rent my milling equipment, I would have to sell them for more.
Polycarbonate is easy to machine. You can drill it, cut it with a saw, sand it with a belt sander or mill it easily. No nasty lung irritants like with fiberglass. No nasty smells or toxic fumes like phenolic unless you run your tool speed to high and then it starts melting and gooing up the bits.
Polycarbonate is slightly flexible. When you hit something with it, it flexes just a bit, reducing the shock to your arm. In that sense it is more like wood. You can scratch it, but you can't break it with normal human strength. That is why they use it in bullet proof glass, riot gear and shooters glasses.
To the couple people who wanted "deals". I don't know that I want to get into making polycarbonate fighting sticks for the world, but I might be talked into making up a few extras and bringing them to the Las Vegas seminar at the end of January.
