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bobbiker: Cut off the bottom end of the pump to the desired length. Here i took a 56 cm pump and cut off about 6 cm
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bobbiker: I cut off all but the bottom cm or so of the pump from the plug, and chucked it up in my drill press. Then used a rasp and file to file off the bottom of the tube from the plug until it just fits in the tube.
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bobbiker: Here is the bottom plug ready to go into the tube
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bobbiker: Plug fits in the tube with just enough clearance for epoxy to work well. A slip fit. Epoxy it into the tube.
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bobbiker: Now cut off equivalent amount of the plunger.
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bobbiker: File off the end of the plunger square and smooth.
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bobbiker: Cut off all but the bottom cm of the plunger tube and then file though it to release it from the plug.
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bobbiker: Now ready for the plug to go into the plunger tube.
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bobbiker: I staked it in using a center punch, supporting it on the curved surface on the back of my vise, just like it was assembled originally.
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bobbiker: Pump assembled except for the handle and end.
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bobbiker: Put it back on the bike now.