After reading several hundred pages I decided to stop using the somewhat shaky and slow to set up rig I just bought around Christmas and decided to build my own DIY rig.
I went to Industrial Metal Supply and picked up 5 pre-cut 44" sections of "remnant stock" 6061 T6 aluminum 2" OD ⅛" wall tube, and a 50" section of 1.75" OD ⅛" wall tube to use as 4 slip-fit joints. I then took them to a local machine shop and had them drill holes, cut and turn down the 1.75" inner tubes just a bit so they would fit. In addition, they went ahead and inserted the 4 inner tubes into the 2" tubes, epoxied them in and added studs so there would be zero play. They did an awesome job.
Though there are 2 holes on either side drilled, I find that the tolerance is so tight that I only need to secure each joint with 1 bolt. I'm thinking of going to pick up quick release pins to make setup and break down even faster. Currently I'm using ¼-20 x 2.5" stainless steel bolts, washers and nuts.
Total weight of this 5-section 18.3 foot rig pole with hardware is 19lbs.
Total spent on the poles, machining and joiner hardware: ~$195
In order to protect the ends of the tubes from dings and scratches in transport and storage, I went to mcmaster.com and for $20. bought 1.75" and 2" ID vinyl end caps. (I have 5 extra 1.75" ID end caps if anyone wants them)
For storage and transport I bought a 50" OnStage padded speaker stand bag, and Amazon Basics packing cubes. The storage cubes are of a thin nylon material with a mesh top, so I'm not sure how long they're going to hold up but at their price they're worth a shot. It's a tight fit, but everything fits and the tubes don't move around.
Bag weight with the entire kit in it is a whopping 42lbs.. Just a bit heavier than I was expecting, haha.
Kit includes:
- 5-section 18.3' pole with joiner hardware
- 2 Manfrotto and 1 filmtools 6" suction cups
- Avenger swivel head and 3" and 6" threaded pin extensions
- 4 Manfrotto superclamps
- Manfrotto camera plate
- Kupo Max Arm
- Vertical coated steel cable tension support system
All I really want to do now is swap out these 2 manfrotto cups for more flexible Rig-Pro cups and swivels, and get the Rig-Pro 10" cup to rig and 30" rig to camera extension bars.
Test of the new rig:
This rig oscillates much less than the last one, is faster to setup and break down, especially when I'm by myself, and is much easier for me to transport.
IMAGE LINK: https://photos.smugmug.com …i-FMKKGdx-XL.jpg&lb=1&s=A 
