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This subject has come up before with regard to being almost new. My own theory is that it can be caused by the ends of poles being placed heavily against the floor during handling, thus crushing the elastic, as it is exposed when the poles are folded up. Could also happen during handling before purchase. The metal ferrules can be quite sharp.

As I say, only my theory.

Quote: Originally posted by loganberry on 25/5/2009

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Is it quite easy to re-thread the poles then? Eager to get it fixed quickly so we can go camping again soon! But also want the repair to last

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Five minute job. But it also illustrates why you should carry spare shock cord, spare pole sections, ferrules and a few spares of other things like guylines, pegging rubbers, sliders, pegs ert. And some needles, strong thread and a pair of scissors. It's a lot easier to do a small tent repair on the spot, usually, than let it turn into a big problem.

hi sorry to hear about your pole problem, i have the same problem .

i have been trying for quite some time to fix my poles i cannot thread my pole its not the new i broe but one that had the elastic thru before but now it will not go thru good luck i am off to buy a full new set .

http://cgi.ebay.co.uk/TENT-POLE-ELASTIC-CORD-REPAIR-camping-equipment-spares_W0QQitemZ160336673848QQcmdZViewItemQQptZUK_SportsLeisure_HikingCamping_Tents_JN?hash=item2554cf7c38&_trksid=p3286.c0.m14&_trkparms=72%3A1688%7C66%3A2%7C65%3A12%7C39%3A1%7C240%3A1318%7C301%3A1%7C293%3A1%7C294%3A50

Is that any help?  I found it while searching for something else and remembered your thread.