How to Make the Perfect Hoop Connection

About this video

A hoop's connection is the seam where the two ends of the tubing meet around an internal connector (the insert). Getting it right is what separates a hoop that holds a true circle from one that slowly drifts egg-shaped. This tutorial covers how to make that connection perfect on a polypro hoop — the preparation that happens before you install the rivet and push button.

Start by cutting your tube slightly longer than the exact hoop circumference (about 1/4 inch over for a bare or beginner connection) so you have material to work with for a clean join. Cut your connector to length as well — typically a 2- to 3-inch piece. Polycarbonate inserts give the straightest, most rigid connection; polypro works well and follows the tube's natural curve, making it ideal for larger hoops; HDPE is softer, less rigid, and more prone to creating teardrop-shaped hoops over time, so we rarely use it for inserts.

The key to a perfect connection is fit. The insert should slide snugly into the tube — if it's too tight to push in by hand, the tubing's inner diameter needs correcting with a boring tool (the Freud router bit) before assembly. Manufacturing tolerances mean the inner diameter is rarely exact, so some correction is normal. A connection that's too loose leaves a gap and lets the hoop deform; one that's correctly sized seats firmly with no play.

The goal is a tight connection — one that's actually physically challenging to push together. While that feels counterintuitive, a tighter connection is always better than a loose one: it keeps the hoop perfectly round, leaves no gap at the seam, and prevents the hoop from becoming egg-shaped over time. Once the connection is perfected, you're ready to install the hardware — drilling and setting the rivet on one side and the push button on the other — which we walk through step by step in our "How to Make a Polypro Hoop" tutorial.