Hi Dan:

I know the on line catalog for Edson only shows the 1 1/8" tube guards, but you may want to call them at 508-995-9711, if you haven't already, to see if they have any of the 1" guards left. If not. I'm sure they can make one up for you pretty quickly. Hope this helps.

Dan,
If Edson doesn't have one, or can't make you one, I'm sure that the good folks at Garhauer could make you one in a snap.

Any metal shop could make you one, but Garhauer would probably be my fist phone call.

Dan
I recently modified my pedestal guard when I installed radar. I was shocked by the price of replacement guards, and instrument pods, so I modified the existing guard and mounted the GPS and radar with the trunion mounts that came with them. I was able to make the complete modification without removing the old pedestal guard or the autopilot wiring in it.

A sketch of how I accomplished the modification is attached.

I purchased four 316 SS fittings called 125 degree bow forms for 1" tube, from bosunsupplies.com. These are heavy duty fittings and have a deep socket with double set screws for the tube. These fitting formed the 'bends".

The round top part of the existing guard was sawed off, leaving enough of the straight part on each side to slip into the new bow form elbows.

The only downside of this modification that I found was that the bow forms do not have a passage so wiring can be fed from one tube to the next. This did not cause me a problem, because the radar cables are so large I could not have put them inside a 1" tube.

I think you could made a single bend guard by using two of the bow forms, and two straight coupling fittings.

Remember, measure twice - cut once.

Gary
When I get on the boat I step on the gunal with one foot and swing over the coming and put the other foot on the seat. At this time I grab the pedistal guard for support then step into the cockpit. My question to you is your modifacation strong enought to support the weight I put on it while stepping from the gunal to the seat to the cockpit?

My other question is, What did you use to cut the tubing?

I shortened my pedestal guard a bit and just cut it with a hacksaw. Not quick but not hard.

I would think the modification described above would be plenty strong if SS hardware is used. The chrome Zinc type hardware maybe not so much.

I cut the tubing with a hand hacksaw. I used a good quality blade made for thin material. It only took a few minutes.

The setup is very rigid. I use it as a handhold, and it feels strong.

I drilled and tapped through one of the set screws in each tube to fitting connection and put a 1/2" 10-24 SS machine screw into the tube to be sure nothing slips. The set screws that came with the fittings were a loose fit in their threaded holes, and did not inspire confidence.

I also drilled and tapped into the sides of the new tubes that slant upward and installed a piece of 3/8" plastic to mount instruments to. This plastic plate probably also adds stiffness.

Be sure to use cutting or tapping oil on the drill and tap. Stainless can be tough on tools. I used a cobalt drill.

Gary