How to replace cracked foam handles on old trekking poles?

Foam handles on trekking poles eventually wear out – they crack, crumble, or become slippery from sweat and UV exposure. Replacing them is a simple, low‑cost repair that can give your old poles a new life. This guide covers everything you need to know: from determining if your handles are replaceable, to sourcing new foam grips, and installing them correctly.

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Why replace cracked foam handles?

• Safety: Cracked foam can break off completely, leaving you gripping bare metal or carbon, which is slippery and uncomfortable.
• Comfort: Old foam loses its cushioning, leading to hand fatigue and blisters.
• Hygiene: Cracks trap dirt, sweat, and bacteria, causing odour and potential skin irritation.
• Aesthetics and longevity: A new grip makes old poles look fresh and extends their usable life.

First, determine if your handles are replaceable

Foam grips are typically attached in one of three ways:

1. Friction‑fit only – The foam is simply stretched over the shaft. No glue. Common on budget poles. Replaceable.
2. Adhesive‑backed – A layer of double‑sided tape secures the foam. Replaceable – you will need new tape.
3. Over‑moulded (non‑replaceable) – The foam is bonded to an inner plastic sleeve that is itself permanently fixed to the shaft. If the foam is damaged, you cannot remove it without destroying the grip. You would need to replace the entire top section or buy new poles.

Check your poles: if you see a seam or can feel that the foam is separate from the shaft, it is likely replaceable. If the foam appears to be moulded directly onto a plastic core that is riveted to the shaft, it may not be replaceable.

Tools and materials you will need

• New foam trekking pole grips – available online or at outdoor stores.
• Utility knife or sharp scissors – for cutting old foam.
• Isopropyl alcohol – for cleaning the shaft.
• Double‑sided tape (e.g., carpet tape, 3M VHB) or spray adhesive (e.g., 3M 77) – to secure the new grip.
• Fine sandpaper (220‑400 grit) – optional, to roughen the shaft for better adhesion.
• Hairdryer or heat gun (low setting) – to soften old adhesive or to help slide on tight grips.
• Ruler or measuring tape – to measure and cut the new grip.

Where to buy replacement foam grips in Brazil

• Decathlon – Sells universal foam grips for their Forclaz and other poles. Price around 20‑40 BRL per pair.
• Adventure Sport (adventuresport.com.br) – For Leki and Black Diamond specific grips.
• Mercado Livre / Amazon Brasil – Search for “cabo de espuma para bastão de trilha” or “trekking pole foam grip replacement”. Check compatibility (inner diameter, length).
• Universal aftermarket grips – Brands like Gossamer Gear, Cascade Mountain Tech, or generic foam tubing.

Step‑by‑step replacement procedure

Step 1: Remove the old foam grip

• If the grip is not glued: Slit the old foam along its length with a utility knife. Be careful not to score the metal or carbon shaft underneath. Peel the foam off. If it is stubborn, use a hairdryer to warm the foam (makes it more pliable).
• If the grip is glued: Apply heat from a hairdryer to soften the adhesive. Then slit and peel. Use isopropyl alcohol to remove stubborn glue residue.
• If the grip is over‑moulded: Cut it off in sections. You will be left with a smooth shaft – that’s fine.

Step 2: Prepare the shaft

• Clean the shaft thoroughly with isopropyl alcohol. Remove any old adhesive, dirt, or foam fragments.
• If the shaft is very smooth (e.g., carbon or polished aluminium), lightly sand the area where the grip will sit with fine sandpaper (220‑400 grit). This creates a better bonding surface. Wipe away dust with alcohol.

Step 3: Measure and cut the new foam grip

Universal foam grips are often sold as straight tubes that you cut to length. Measure the length of your old grip (or the section you want to cover). Cut the new foam to that length using a sharp knife or scissors. If you want an ergonomic shape, you can cut the top at a slight angle to match the original.

Step 4: Apply adhesive

• For friction‑fit only (no glue): You don’t need tape. The foam should stretch tightly over the shaft. If it slides, proceed with tape.
• For a secure fit: Apply double‑sided tape along the shaft in a spiral or in strips. Leave a small gap at the ends to prevent oozing. Alternatively, spray adhesive onto the shaft and let it become tacky (follow manufacturer’s instructions).

Step 5: Slide the new foam grip onto the shaft

• If the foam is tight, spray a little glass cleaner or isopropyl alcohol inside the new grip as a lubricant. The lubricant will evaporate, leaving the foam stuck.
• Push the foam onto the shaft with a twisting motion. Work it down until it sits at the correct position (flush with the top of the pole or leaving room for the wrist strap pin).
• If the grip has a contoured shape (e.g., left/right specific), ensure it is oriented correctly.

Step 6: Allow to set and test

• If you used adhesive or tape, let the pole sit for 12–24 hours before using.
• Twist the grip – it should not rotate.
• Check that the wrist strap (if it attaches through the grip) still fits. You may need to drill or punch a small hole for the retaining pin on some poles.

Troubleshooting

• Grip slides after installation: The tape or adhesive failed. Remove grip, clean shaft, and reapply with stronger adhesive (e.g., 3M VHB tape or contact cement).
• Grip is too tight to slide on: Warm the foam with a hairdryer (makes it expand slightly) and use a lubricant (isopropyl alcohol). Do not force it – you could split the foam.
• Grip is too loose: If the inner diameter is too large, wrap the shaft with a layer of electrical tape or foam tape before sliding the grip on.

Alternatives to buying new grips

• Foam tubing (pipe insulation): You can buy EVA foam tubing from hardware stores (sold as pipe insulation for hot water pipes). Cut to length and slide over the shaft. Not as durable as purpose‑made grips, but works as a temporary fix.
• Cork tape: Wrap cork bike handlebar tape around the shaft. Provides a comfortable, sweat‑absorbing grip. Cheap and easy.
• Heat‑shrink tubing: Available in large diameters (25‑30 mm). Slide over the shaft and heat with a hairdryer. It shrinks to form a tight, durable rubbery grip. Very durable.

When to buy new poles instead

If the shafts are bent, the locks are broken, or the poles are very cheap (under 150 BRL), it may be more economical to buy new poles rather than invest time and money in new grips. However, if the poles are quality aluminium with good locks, new grips are well worth the small effort.

Conclusion

Replacing cracked foam handles on old trekking poles is a straightforward DIY project. Determine if the grips are replaceable, cut off the old foam, clean the shaft, and slide on new foam grips with double‑sided tape or adhesive. With a little patience, you can restore your poles to like‑new comfort and safety. New grips cost little and can extend the life of your poles by years. Happy (and comfortable) hiking!