Build a Dan-Bouy

I didn't make mine, but the one that came with the boat appears to be homemade utilising a telescoping fishing pole as the mast and then Jimmy Green Danbouy components. I've had it 10 years, it's be used in MOB drills frequently and still appears robust.
 
I made mine using a 2l coke bottle and a 2m length of overflow pipe (21.5mm). Cut a hole in the base of the bottle a little bigger than the pipe diameter. Push the pipe through the cap end and out through the hole at the bottom. Next drill a hole in the bottle and fill with builder's foam spray. Add weight to the bottom till it floats upright and a ring shackle with which to connect the line. Paint the bottle with a colour of your choice. Job done! Takes no time at all to make and is easy to pick up from the water and lasts for ever.
 
Any idea how to attach an automatic light at the top?
As an ORC one is around 3m length, how to make the light automatic? Bring the two wires down inside the rod?

Also, how to attach it solidly to a thin fiberglass tube? I have used the kite (kite-kite, the coloured ones used by children on the beach, adults also :shy: ) fiberglass tubes, poked inside a swimming pool noodle section, I was hoping to attach a lifejacket light, sort of. The tubes are also available in carbon fiber, maybe better.
 
My research suggests using clear shrink-wrap (heat shrink) tubing to attach wires to the pole. Hollow fishing rod section would do the job too. (Roach pole for instance)
Trickier is how to switch and power the light - which must be both very light and very bright.
I saw one example where 5m of strip LEDs were spiral-wound around the pole and heat-shrunk in place but that requires 12v and I'm not at all confident strip LEDs would be visible at much distance at sea.
 
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The last one I made used a magnetically switched diver's strobe as the light.
But you need a lot of lead as ballast.
ISTR continuous lights are easier to judge distance to than strobes.
LEDs are good enough for EPIRBs these days. But EPIRBs don't have the windage of a 6ft pole tilting them over.
 
I made one from a toilet ballcock float, 3 lengths of fibreglass rod from a tent (joined together with fibreglass), lead melted out of an old battery, and a flag from a high viz vest. Seems to work adequately, cost £2.70.
 
I made one from a toilet ballcock float, 3 lengths of fibreglass rod from a tent (joined together with fibreglass), lead melted out of an old battery, and a flag from a high viz vest. Seems to work adequately, cost £2.70.

Do you sail at night?
 
Anyone made their own and care to describe meterials used, design etc?

My father did it many years ago. Some kind of a metal tube (copper?) filled with lead. That was attached to a broom handle with some kind of a foam cylinder fixed to it. On top of that was a fibreglass rod with a flag. I think it was something that was supposed to be fixed to a bicycle to improve its visibility.
 
Aluminium tube, Foam fenders, a lead weight from fishing sinkers and a flag.

If I were do do it again I would use a fiberglass fishing rod
Not recommended - exactly what I did last year and it broke!! Mind you it was a. hollow telescopic one so maybe a solid one will be ok. I may wrap it in grp to stiffen it
 
If you cannot get a fishing rod you can get fibreglass rods used in tents or awnings from a caravan/camping shop. Quite cheap.
If filling bottles with builders foam, spray in some water to set the foam, otherwise the foam may just turn to goo, as it needs moisture to set, especially in the middle.
Weights, such as 1 lb cast iron "add weights" for sash windows are drilled right through the middle about 10mm for the cords, so the GRP rods from tents fit quite well.
Mighton Products
https://www.mightonproducts.com
Do lead "make weights" which would do the job very neatly

For lights one can use a life jacket light. These are sold individually with their own battery & are bright enough for the top of the pole & not very heavy.
 
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