Category: Construction

This may not seem that radio related but an arbor press is a very useful tool, even if it is not used that often. Most recently I have used it to press in my YBB washers into Stauff clamps for an antenna build. I’m tuning it up in order to use a 5 inch vice based brake press set to do some sheet metal folding, mostly as I don’t actually own a vice to use the brake press set in but also because if I did I would only have a couple of inches of throat to bend whereas the arbor press will give me about 5 inches. These are great tools and not expensive but out of the box they don’t feel or work that great so I decided it needed a simple tune-up.

I actually bought an arbor press because I could get what I really wanted which was a lever press RS (Radio Spares) used to sell. If you have one of these in good condition, I need it!!

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This was another Covid lockdown project in 2020 to enable me to do some over the air audio checks with locals and maybe give some points away in contests to the locals (my QTH is very poor for VHF/UHF). I wanted something small I could put in the attic. I figured a simple DK7ZB dual band 2m/70cm yagi in the loft with a single feeder would be ideal.

on this page:
https://www.qsl.net/dk7zb/Duoband/4+5_2m-70cm.htm

Martin DK7ZB describes his design for a single feed dual band yagi with 4 elements on 2m and 5 elements on 70cms on a compact 1m long boom.

I already have my element cutting jig  (see here) so cutting the elements was easy enough as usual. I went for the 8mm elements to make it nice and light.

To assemble it I decided I would 3D print not just the dipole box but also the element mounts themselves. The beauty of this over commonly used mounts like the Stauff clamps (see here) is I could design in a feature to ensure the elements are nice and perpendicular to the boom. I also don’t like drilling my tubular elements. For a start it weakens them and also adds a place for inaccuracies to creep in.

So this was my design for the element mount:

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So many commercial and home brew constructors use Stauff type clamps for attaching yagi elements to the boom but I have until now avoided these because I hate the huge bolt holes that are typically at least 6.5mm in diameter which is sloppy even on a grossly overkill M6 bolt. Of course these clamps were not designed for making antennas but are extremely useful as they come in pretty much every tube diameter there is. So after many builds avoiding these clamps I decided to come up with a way to use them that would satisfy my exacting standards. One night instead of being able to sleep I came up with the YBB washer.

Usually instead I have been making my own elements mounts in some way or other but I am building some HF beams and it’s just convenient to use off the shelf Stauff clamps so I decided I needed to do something about this issue. I recently assembled a commercial beam that had a tapped boom so next to no slop bolt to boom but you could move the element side to side about ±6 inches or more at the ends of a 50MHz element. I had to use a square to mount them: continue reading

It’s time that the saying about sliced bread was replaced with 3D printers. They are right up there with the internet in ‘how did we manage without it’ in my opinion. For the radio amateur they uses are never ending!

The yagi below is completely assembled with 3D printed parts. Not only that it’s mounted to a 30mm pole with 38mm U bolts using 3D printed reducers and the guy ring has an integral 3D printed plastic bearing.

Not only that the DK7ZB match coaxes were precision cut on a 3D printed cutting jig. — continue reading

Having recently received my new (2nd hand) short contest callsign I was keen to air it and with probably the biggest contest in the world, CQ WW SSB, coming up I decided I would try a single band entry and build a moxon that was as lightweight as possible to use after how well my 50MHz moxon performed for me. This page describes my lightweight 20m moxon build.

First step was the trusty Moxgen application and give it the wire size to get my start dimensions. As with the 50MHz moxon I then used 4NEC2 to recalculate the sizes for insulated wire as I was using.

This gave me this predicted radiation plot: continue reading

At my location it’s very difficult to have any sign of HF antennas (or any antennas for that matter) up in the garden. I’m already using a covertly erected dipole after dark using this quick erect fishing pole mount. But I was very interested in an ATU free multiband antenna. The hexbeam is nice but too big and needing a rotator. So I looked at the G3TPW Cobwebb antenna. For those unaware this is a 5 band dipole based antenna horizontally polarised and roughly omnidirectional working on 10, 12, 15, 17 and 20m. The folded dipole style with shorting points seemed more complicated than I fancied so I looked at the simpler G3TXQ cobweb design. This filled more boxes for me, single wires nice and easy to tune and a tidy looking feed box. However, it would still stand out in the garden due to it being some strange looking (to non hams) spoked wire thing. What I decided to try was up sweeping the spreaders to make my G1YBB Disguised ultralight Cobweb antenna look like a rotary washing line as there is already one in my garden. I was counting on the neighbours not noticing it had grown an extra arm and got a bit bigger. Except when actually in use I would keep it low down like a normal washing line such as this:
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The coronavirus outbreak of 2020 put a stop to all portable radio activities so like many people I was forced to adapt and overcome and set up something at home. For non rotating mast systems I strapped a mast to the YL’s parasol base:

This worked for smaller dipoles but I wanted something a bit sturdier and the YL wanted her umbrella back! So I decided to make a new one. I thought about making something from scratch but after asking the local club members for ideas it was suggested to use a tamper that builders would bash sand down before laying slabs or bricks. A quick Google located one in stock in the local Toolstation: continue reading