EME Station 2.0 Part 7 – Building Antennas

M2 Antennas 2MXP28 X-Pol Yagi

M2 Antennas 2MXP28 X-Pol Yagi

The next step in our EME project is to assemble the four M2 Antenna Systems 2MXP28 Yagis. These antennas are large, cross-polarized yagis. They feature 28 elements each on 34 1/2 foot booms. The design operates as an independent horizontal and vertical Yagi on a shared boom and each plane has an independent feedpoint.

EME Antenna Array Assembly

EME Antenna Array Assembly on H-Frame

We are building four of these antennas to be mounted on an M2 Antennas 2X2 H-Frame. It is important that the four antennas be identical so they operate properly as an array. This includes things like symmetrical mounting and alignment of each antenna’s vertical and horizontal elements and the associated feed points. We will cover the assembly of the H-frame and Elevation Rotator systems in the next article.

Preparation

NOALOX Assembly Compound and Sharpie Pen

NOALOX Assembly Compound and Sharpie Pen

M2 Antenna Systems instruction manuals are very good and they specify the tools and procedures to properly assemble the associated antennas. A few additional items were helpful in our project. These included:

The assembly steps and procedures are similar for most M2 Antennas 2m and UHF Yagi antennas so I’m going to share some details and a few tricks that we’ve used successfully to build a number of their Yagis. You can see some of these other projects via the following links:

We successfully built all of these antennas using similar components and techniques.

M2XP28 Sorted Parts

M2XP28 Yagi Sorted Parts

The first step in assembling each antenna was to inventory and arrange all of the parts. I also took the time to wipe the boom elements with a solvent soaked cloth to remove dirt and aluminum dust that results from the manufacturing process. This makes assembling the antenna a much cleaner process.

2MXP28 Yagi Dimension Sheet

2MXP28 Yagi Dimension Sheet

M2 supplies detailed dimension sheets and boom layout diagrams with their antennas and we took the time to carefully identify each element and boom component according to the diagrams.

Element Measurement and Marking

Element Measurement and Marking

This step included careful measuring, sorting, and marking each element with its location and polarity (horizontal or vertical). This step makes the somewhat difficult step of getting all of the elements in the correct polarity and orders much easier. The marks allowed me to check and confirm the correct installation of all of the elements on the antenna boom before locking them in place.

Mast Clamp and Boom Truss Attachment Pre-assembly

Mast Clamp and Boom Truss Attachment Pre-assembly

We also pre-assembled things like the Mast Clamp and the Boom Truss Clamp during the parts inventory process.

Boom Assembly

Boom Assembly Details

Boom Assembly Details

The first step in assembling the antenna boom was to arrange all of the boom segments in the correct order and confirm their front/back orientation. This took some time to get right on the first of the four antennas. Each Boom segment was marked with the Sharpie to indicate its location and orientation in the final assembly.

We also installed the T-Brace Clamp to attach the rear of the antenna to the H-Frame’s T-Brace. It’s essential to do this step before assembling the Boom as the clamp cannot be attached once the antenna’s elements are in place. The correct location for the clamp was established via a careful measurement and the location was marked on the boom using the Sharpie.

Assembled Boom

Assembled Boom

The next step was to assemble the boom sections paying careful attention to the markings made earlier. We did not tighten any of the bolts that hold the boom sections together at this stage to allow us to re-clock each boom section for the best alignment of the elements later. A generous coat of NOALOX was used at the joint of the two largest diameter Boom sections to facilitate easier assembly and potential re-clocking later. NOALOX was also used on all bolts to provide anti-seize lubrication.

Once the boom is assembled, a 40-foot tape measure is used to carefully confirm that all of the holes for the elements are in the correct location. The Dimension Sheet is used as a reference to check and confirm that all measurements are correct before installing the Elements. This is also a good time to measure and carefully mark the location of the center of the Mast Clamp on the Boom.

The eye bolts that attach the Boom truss cable are also installed at this time.

Element Installation

Element Installation Details

Element Installation Details

Next came the installation of the elements. We began with the Horizontal reflector and worked towards the front of the antenna. The elements are held in place with insulated buttons and stainless locks. The elements are first installed in the correct location and carefully centered using a steel ruler. Vise-grip pliers are then used to hold the element in its centered position while the M2 supplied tool is used to push the lock on the opposite side of the element. The center is next checked again and if all looks good, the second lock is installed. This process is continued until all of the elements are in place. We pay careful attention to the markings on each element as part of the installation procedure to ensure that all of the elements are in the correct location on the boom.

H-Element Installation Complete - Ready for V-Element Installation

H-Element Installation Complete – Ready for V-Element Installation

Once all of the elements are in place, the antenna is rotated 90 degrees to enable boom adjustments to align the elements. It is common for the boom sections to be misaligned a bit after the initial assembly. A combination of clocking each boom section either a bit one way or the other or sometimes removing the bolts holding two sections together and turning them 180 degrees relative to each other will create a perfect alignment of the elements. Once this is done, all of the bolts that hold the Boom sections together are fully tightened taking care not to distort or crush the Boom tubes.

The same installation process is repeated for all of the vertical elements.

Driven Element Assembly

Feedpoint Assemby

Feedpoint Assembly

The Driven Element feedpoint blocks are installed next. The mounting screw and the Allen screws in the Shorting Bars all receive a light coat of Blue Locktite thread locker prior to installation.

Next, we loosely install the blocks in their correct location on the Boom and then install the Shorting Bars loosely on the Feedpoint Block and Driven Element. Once these parts are in place, the screen that holds the Block to the Boom can be tightened fully, guaranteeing a perfect alignment of all of the parts.

The next step was to accurately set the spacing between the Feedpoint Block and each shorting bar. I used a dial caliper to do this accurately but it can also be done with the careful use of a metal machinist’s or similar ruler.

The final step for each feedpoint was to install the 1/2 wave Coax Balun to the Feedpoint Block. Be careful not to overtighten the coax connectors. Just make them snug and you are set. The supplied cable ties are used to secure the Balun to the boom.

The same steps are repeated for the Vertical Feedpoint. It’s a good idea to install connector dust caps on the Feedpoint Block connectors to keep them clean and dry prior to installation.

H and V Feedpoint Orientation

Vertical and Horizontal Feedpoint Orientation

It is critical that the relative orientation between the Horizontal and Vertical Feedpoint Blocks be the same on all four of the antennas in the array. If this is not the case, the pattern of the array will be upset which will have a major negative effect on the array’s performance.

Mast Clamp and Boom Truss

Mast Clamp Installation

Mast Clamp Installation

The Mast Clamp assembly is installed next using the center mark placed on the Boom earlier. I also marked the backside of the Mast Clamp plate to show its center to make lining things up easy. The clamps should be oriented according to the H-frame mounting diagram (show at the front of this article).

Boom Truss Assembly

Boom Truss Assembly

The final step in the assembly process is the assembly of the Boom Truss. The 2MXP28 Yagi is supplied with a Phillystran cable. The height of the Boom Truss will be set later when the antennas are attached to the H-frame so we just installed both ends of the Phillystran cable to the Eye Hooks installed in the Boom. The connections are made using the supplied Strain Relief Loops and small cable clamps. A drop of oil on each nut helps things go together smoothly.  We had some Phillstran cable end caps so I installed them on the Phillystran cable ends to protect against water ingress. The turnbuckles, remaining clamps/strain reliefs, end caps, and truss clamp assembly were stored in a plastic Ziploc bag and cable-tied to the Boom to be installed later when the antennas are attached to the H-frame.

Final Details…

Completed 2MXP28 Antenna Ready for Installation

Completed 2MXP28 Antenna

It’s a good idea to give everything one last go-over now that the antenna is complete. All bolts and screws are checked for tightness, the Elements are all confirmed to be in the right locations, and the Feedpoint assemblies are given a final check.

Four 2MXP28 Antennas Ready for Installation

Four 2MXP28 Antennas Ready for Installation

Our EME project involves the assembly of four of these antennas with a total of 112 elements! It took me about 3 days to assemble each antenna (working about 3-4 hours each day). We stored the antennas on our deck to make space in our shop as we went. The antennas are well supported using low saw horses and woodblocks so as not the bend the Booms or the Elements.

The next step in our project will be to assemble and test the Elevation Rotator system. You can read more about our EME station project via the links that follow:

If you’d like to learn more about How To Get Started in EME, check out the Nashua Area Radio Society Teach Night on this topic. You can find the EME Tech Night here.

Fred, AB1OC

6m VUCC In A Day – ARRL June VHF Contest

6M VUCC Operating Award

6M VUCC Operating Award

The 6m Band is one of my favorite bands. The combination of its unpredictability and the amazing openings that it can produce certainly makes 6m The Magic Band for me!

Fred’s (AB1QB) First Place Finish in NH – 2013 ARRL June VHF Contest

Fred’s New Hampshire First Place Finish in the ARRL June VHF Contest

I haven’t had the chance to work the ARRL June VHF Contest from our home station for several years. A combination of Nashua Area Radio Society activities and preparations for ARRL Field Day have taken a higher priority. ARRL June VHF is a great contest and I was looking forward to working it this year. A few days before the contest Anita and I were talking about the contest and she suggested that I do a 6m Digital Entry. E-skip has been pretty good on 6m this year and we wanted to sort out how we’d do digital and 6m for our upcoming 2020 Field Day Operation from our home so I decided to take Anita’s advice and focus on 6m Digital for June VHF. I entered the contest in the Low-Power Category.

June VHF Operating Setup

6m VUCC

AB1OC Operating in 2020 June VHF

We built a Remote Operating Gateway that allows our station to be operated both over the Internet and from any room in our home via our Home Network. I decided to set up a 6m Digital Station upstairs in our dining room so I could be with Anita more during the contest. The setup consisted of a laptop PC with an outboard monitor and a Flex Maestro as the client for the Flex 6700 SDR in our shack.

Completed Antenna Stack On New Tower

Completed Antenna Stack on our VHF Tower

We have three antennas for 6m – one on our VHF Tower and two via the SteppIR DB36 yagis with 6m kits on our main tower.

Delta Loop On Tower

SteppIR DB36 Yagis on our Main Tower

The three antennas can be pointed in different directions and selected instantly via the computer. This provided to be an advantage during the contest. I kept one on Europe, one point due West, and the third pointed at the Tip of Florida and the Caribean during the contest.

6m VUCC

Operating Setup – N1MM+ and WSJT-X

Having two monitors (the Laptop and an outboard one) allow me to arrange all of the N1MM+ Logger and WSJT-X windows for efficient operating. The image above shows a snapshot of the screen layout during the contest. N1MM+ has some nice features that integrated with WSJT-X to make it easy to spot new grids (Multipliers) and stations that have not yet been worked. The windows on the very right side allowed me to control antenna switching and monitor power and SWR while operating. I use the PSTRotator application (lower-left center to turn my antennas.

6m Band Conditions

6m VUCC

6m PSK Reporter On Sunday Evening

Band conditions on 6m were amazing from here in New England almost the entire contest period! The band was open right at the start of the contest on Saturday and remained open to 11 pm local time on Saturday evening. I was up early on Sunday and was working folks in the Northeastern Region right from the start. After being open all day on Sunday, the band shut down around 5 pm local time and I was afraid that the fun on 6m might be over. I ate some dinner and took a 45-minute nap and got back to my station at around 6:30 pm. About 15 minutes after I resumed, 6m opened again to most of the United States and I was able to work DM and DN grid squares in the Western States! The band stayed open right until the end of the contest at 11 pm local time.

What About the VUCC…

6m VUCC

100 Grids Worked on 6m

Conditions on 6m were so good on Saturday that I almost worked a 6m VUCC by 11 pm on Saturday evening when the band closed. I had 93 grids worked on 6m in just 8 hours! The band opened again early on Sunday morning and I worked my 100th grid square before 10 am – working a 6m VUCC in less than 18 hours!

6m VUCC

Final 6m Grids Worked

By the end of the contest, I had worked a total of 162 Grids! They ranged from the West Coast of the US to Western Europe and from Southern Canada to Northern South America.

6m VUCC

6m Grids Worked During 2020 June VHF

The image above shows most of the 6m grids that I worked plotted on a world map (the EU grids are not shown).

6m VUCC

Final Claimed Score

I was able to make a total of 402 unique contacts on 6m by the end of the contest with a final Claimed Score that was a bit over 65K. All of my 6m contacts during the contest were made using a combination of FT8 and FT4 modes on 6m.

New Ones on 6m for AB1OC

6m VUCC

AB1OC Worldwide 6m Grid Map

I was hoping to work some all-time new Grids and June VHF did not disappoint. I worked a total of 11 new Grids and one new DXCC (Dominica) on 6m during the contest. The image above shows my worldwide grid coverage including the new ones worked during June VHF (my grids in Argentina and Uruguay are not shown above). I now have worked 432 grids on 6m and have confirmed 408 of them with 63 DXCC’s worked and 62 confirmed on the Magic Band.

Summing It All Up…

I must say that I had as much fun working 6m during June VHF this year as I have ever had in any contest! The band openings on 6m were really good and I was busy making new contacts for the entire time that I operated. The combination of the 6m Band and the contest certainly made some Magic for me!

Fred, AB1OC

Getting Started With Amateur Satellites (and Progressing to Linear Birds)

Get Started with Amateur Satellites

Get Started with Amateur Satellites

We get quite a few requests from folks to explain how to get started with Amateur Radio Satellites. Requests for information on how to build a computer-controlled ground station for Linear Satellites are also pretty common. I recently got such a request from our CWA class so I decided to put together a session on this topic.

We covered a number of topics and demonstrations during the session including:

  • How to put together a simple station and work FM EasySats with HTs and a handheld antenna
  • A recorded demonstration of some contacts using FM EasySats
  • How-to build a computer-controlled station and work Linear Transponder Satellites
  • Fixed and Portable Satellite Station Antenna options
  • A recorded demonstration of some contacts using Linear Satellites
  • How-to work digital (APRS digipeater) contacts
  • How-to receive SSTV Transmissions from the ISS

About 30 folks attended this session and there was some good Q&A throughout.

Getting Started With Amateur Satellites

The presentation was recorded and can be viewed above. Here’s a link to the associated Powerpoint Presentation.

There are lots of articles about building and operating Amateur Satellite Stations here on our blog. The following are links to several articles and series on this topic:

I hope that you find this information useful for your Amateur Satellite projects!

Fred, AB1OC

EME Station 2.0 Part 6 – Tower Grounding System

Tower Ground System

Tower Ground System

Now that spring is here, we’ve continued work on our EME station project. The most recent project was to build complete the ground system for our new EME tower. The proper way to ground a tower is shown above. Each leg of the tower is connected to an 8′ ground rod via a heavy-gauge ground cable. The cable is attached to the tower leg using stainless steel clamps meant for this purpose. The three ground rods associated with the tower legs are then bonded together using a heavy copper ground cable ring.

Ground Cable CAD Weld

Ground Cable CAD Weld

The ground cables are welded to the top of the ground rods using CAD weld on-shots. This creates a strong connection that will not corrode or fail. It is important that the ground rods be free of dirt, corrosion, oxidation, and burrs before performing the CAD welding. We used a combination of 3-wire and 4-wire one-shot CAD welds to build our ground system and connect it to the bonding system running from out tower to the entry to our shack.

Main Grounding System Bonding

Main Grounding System Bonding

The final step was to connect the bonding run from the tower to the perimeter grounding system around our house. This completed the tower grounding system and enabled us to complete our final permit inspection courtesy of our local building inspector.

Finished Tower Base

Finished Tower Base

With all of this work done and the inspection complete, we added a mulch bed around our new tower to make this area of our lawn easy to maintain.

The next step in our project is to begin building the antennas that will go on our EME tower. You can read more about our EME station project via the links that follow:

If you’d like to learn more about How To Get Started in EME, check out the Nashua Area Radio Society Teach Night on this topic. You can find the EME Tech Night here.

Fred, AB1OC

EME Station 2.0 Part 5 – Control Cables and Rotator Controller

Control Cable Junction Box on EME Tower

Control Cable Junction Box on EME Tower

Snow is coming to New England this weekend so we wanted to get the control cables run to our new EME Tower before the ground is covered with snow. The project involved installing a Utility Enclosure on our tower and running three control cables to our shack for the following devices:

Az-El Rotor and Preamp Switching Control Connections

Az-El Rotator and Preamp Switching Control Connections

We began by install some barrier strips and a copper ground strap in the Utility Enclosure. The copper strap provides a good ground connection to the tower and associated grounding system. The enclosure is clamped to the tower using two stainless steel clamps.

We ran three new control cables through the conduits that we installed between the tower and our shack and terminated them in the utility enclosure. We only needed 6 leads for control of the planned MAP65 Switching and Preamp System which will go on our tower later so we doubled up some of the higher current connections using two wires in the 8-conductor cable.

Green Heron RT-21 Az-El Rotator Controller

Green Heron RT-21 Az-El Rotator Controller

The final step was to hook up our rotator cables to a Green Heron RT-21 Az/El Rotator Controller in our shack.  We do not yet have our elevation rotator so we tested the M2 Orion 2800 Azimuth Rotator that is installed in our tower. The azimuth rotator is configured so that the rotator’s dead spot faces north. This is a good configuration of our planned EME operation.

With all of our control cabling in place, we are ready to begin preparing our Antennas, Elevation Rotator, H-Frame, and MAP65 components to go on our EME Tower. We’re hoping that the weather will cooperate and enable us to get these steps completed during this winter.

Here are some links to other articles in our series about our EME Station 2.0 project:

If you’d like to learn more about How To Get Started in EME, check out the Nashua Area Radio Society Teach Night on this topic. You can find the EME Tech Night here.

Fred, AB1OC

Winter Field Day VHF+ Preparations

Jamey AC1DC with Completed WFD VHF+ Mast

Jamey AC1DC with Completed WFD VHF+ Mast

We are continuing to make progress on our preparation for VHF+ Operations at Winter Field Day (WFD) 2020. We had a lot of fun on the VHF+ bands at WFD 2019 and we are planning to add some more bands for our operation this year. We’ve assembled a portable mast system to put us on 3 new bands…

Source: Winter Field Day VHF+ Preparations – Nashua Area Radio Society

We’ve been busy with preparation for Winter Field Day 2020. My part of this project is to increase our participation in operations on the VHF+ bands (6m and above). We are accomplishing this with a 30 ft push-up mast, some new antennas, and using Transverters for the 1.25m and 33cm bands. You can read more about our preparations and the equipment that we will be using on the VHF+ bands via the link above.

Fred, AB1OC

EME Station 2.0 Part 4 – New EME Tower Is Up!

Three Tower Antenna Farm

New EME Tower in Our Antenna Farm

Our goal for this phase of our EME Station Project is to get our new tower up, install the Azimuth Rotator and Mast, and run the hardline and coax cables for our antennas from the shack to our new tower. Our EME tower is constructed using Rohn 55G tower sections. It will be 26 ft tall and will have approximately 18″ of our 3″ mast protruding above the tower. The tower is a free-standing/guyed hybrid design with the first section being cemented into the ground.

EME Tower

FInished Tower Base

The base section and the three guy anchor blocks were completed a little while back. The holes were backfilled and we’ve given the cement a couple of weeks to cure.

First Tower Section Installed Using a Gin Pole

First Tower Section Installed Using a Gin Pole

Matt, KC1XX, and Andrew of XX Towers began by installing a winch and a gin pole on the base section of the tower. They used the Gin Pole to hoist the second tower section into place and secure it. They also attached the top plate to the third tower section in preparation for installing it along with our mast.

Mast and Top Tower Section Going Up

Mast and Top Tower Section Going Up

It is always a challenge to install a mast inside a new tower. The mast we are using is a heavy, 22 ft 4130 chrome molly steel mast that weighs over 250 lbs. Getting the mast inside the tower was quite a feat! Matt and Andrew rigged the top tower section and the mast together and pulled both up together on the Gin Pole. Next, one leg of the top tower section was attached and a second pully was used to pull the mast up through the top tower section until it could be placed inside the tower. The last step was to raise the top tower section a second time using the Gin Pole to seat it on top of the rest of the tower. Finally, the mast was lowered inside the tower to the base and the top tower section was bolted on to complete the tower.

Upper Guy Anchor Bracket on Tower

Upper Guy Anchor Bracket on Tower

The next step involved attaching the upper guy anchor bracket to the top section of the tower and rigging the guy anchor cables. We decided to use Phillystran Guy Cable to avoid interactions with our antennas.

Guy Anchor Cable

Guy Anchor Cable

The completed cables are tensioned using turnbuckles. We adjusted the cables to plumb the tower and then safety-wired the turnbuckles so they will not come loose.

Azimuth Rototor in Tower

Azimuth Rotator in Tower

The next step was to install an M2 Antenna Systems Orion 2800G2 Azimuth Rotator in our tower. The use of the 22 ft mast allowed us to place the rotator about 5 ft above the ground where we can easily service it in the future. The long mast also acts as a torque shock absorber when the rotator starts or stops moving suddenly. With the rotator in place, we attached the mast and clamped it at the rotator and thrust bearing at the top of the tower.

Tower Base, Coax Feedlines, and Guy Anchors

Tower Base, Coax Feedlines, and Guy Anchors

The last step in our project was to install our coax cables and hardlines on the tower and run them through a 4″ underground conduit to our shack. We pre-made the two LMR-600 coax cables for the receive side of our EME Antenna System previously. We cut a section of LDF5-50A 7/8″ Hardline to approximately the same length as the LMR-600 coax cables.

Pushing Coax Cables and Hardline Through the Condui

Pushing Coax Cables and Hardline Through the Conduit

We used a cutoff plastic bottle to protect the ends of the coax cables and hardline as we pushed them through approximately 50 ft of buried 4″ conduit. The conduits were constructed to create a gradual turn into and out of the ground and the cables went into the conduit smoothly.

Coax Cables Exiting the Conduit Near Our Shack

Coax Cables Exiting the Conduit Near Our Shack

With the cables in place, we installed N-female connectors on each end of the 7/8″ hardline. We used rubber reducers to make it easier to deter water from entering the conduits where the cables exit.

Coax Cable Ground Block Connections

Coax Cable Ground Block Connections

We expanded out main shack entry ground block using an 18 position tinned cover ground bar from Storm Copper to make room for additional static arrestors for our EME Antenna System. The LMR-600 receive-side coax cables and the 7/8″ hardline connection for the transmit-side of our EME antennas terminate on N-connector Static Arrestors from Alpha Delta.

Completed EME Tower

Completed EME Tower

Our new EME tower is up and ready to accept the Elevation Rotator, H-Frame, and Antennas from M2 Antenna Systems when they arrive. We plan to complete the grounding system and get the Azimuth Rotator hooked up and tested with our Green Heron Engineering RT-21 Az/El Rotator Controller in the near future.

Here are some links to other articles in our series about our EME Station 2.0 project:

If you’d like to learn more about How To Get Started in EME, check out the Nashua Area Radio Society Teach Night on this topic. You can find the EME Tech Night here.

Fred, AB1OC

EME Station 2.0 Part 3 – Phase Tuned Receive Coax Cables

Measuring Coax Cable Electrical Length Using a VNA

Measuring Coax Cable Electrical Length Using a Vector Network Analyzer (VNA)

Our new 2M EME station will have Adaptive Polarity capability via MAP65. MAP65 requires that received signals from the Horizontal and Vertical planes of our antennas arrive at the receivers in our shack precisely in phase with each other.

We decided to use a pair of LMR-600 coax cables for the receive side of our feedlines. We made these cables from an unterminated length of LMR-600 coax measured to cover the distance from the top of our planned 26 ft EME tower to the ground block at the entry to our shack. The cables are approximately 82 ft long and they must be cut to be equal in length to with 1/16″!

The easiest way to measure the length of an unterminated coax cable is to determine the minimum frequency of resonance of the cable when the opposite end is an open circuit. One can then use the speed of light and the velocity factor of the cable to compute its exact length:

Length = (Speed of Light X Velocity Factor) / (Resonant Freq. X 4)

Doing these measurements with an open circuit at the far end of the cables enables trimming the length of the two cables to be matched in small increments until our two cables are exactly the same length.

VNA Measurement of Open Coax Cable Resonance

Vector Network Analyzer (VNA) Measurement of Open Coax Cable Resonance

We used an Array Solutions VNA 2180 connected to a Windows PC to precisely measure the minimum Resonant Frequency of our LMR-600 coax cables as we trimmed them. Once they were equal in length to within 1/16″, we installed an N-Female connector on the unterminated end and re-verified each cable’s length. A frequency accurate antenna analyzer can also be used to make these measurements.

We will need to repeat these steps of the receiver-end and antenna preamp box jumper cables which will make up the rest of the receive side feedlines for our EME antenna system once these components are installed. We also plan to make a final end-to-end measurement of the receive-side feedline assemblies to fine-tune the phasing of the completed feedline runs.

With this step complete, we are ready to put up our new tower and attach the feedlines. Here are some links to other articles in our series about our EME Station 2.0 project:

If you’d like to learn more about How To Get Started in EME, check out the Nashua Area Radio Society Teach Night on this topic. You can find the EME Tech Night here.

Fred, AB1OC

EME Station 2.0 Part 2 – Excavation, Footings, and Conduits for New Tower

EME Tower

FInished Tower Base and Cable Conduits

The first part of our EME project is to put up a new tower to support our antennas. Our plans call for a 26′ tower built using three Rohn 55G tower sections. Four feet of the first section of the tower is cemented in a concrete footing to anchor the tower’s base. The tower is also going to be guyed to ensure that it is very stable.

EME Tower

Digging Footings for our New Tower

We are working with Matt Strelow, KC1XX, and Andrew Toth of XX Towers to put up our new tower. Matt brought out his tractor and dug the footings for our tower and for the associated conduits that will carry coax and control cables to our shack. The photo above shows the completed hole and form for the main tower base. Matt is working on the footings for one of the three guy anchors.

EME Tower

First Tower Section and Rebar Cage

Here’s a closer look at the tower base. The footing includes a rebar cage to reinforce the concrete footing. There is also 6″ of crushed stone in the bottom of the hole that the tower legs sit it. It is very important that the bottoms of the tower legs remain open and do not become plugged with cement so that water in the legs can drain. If the legs cannot drain properly, water will accumulate and freeze. This can split open the tower legs and ruin the tower.

EME Tower

Cable Conduits with Drains

We also installed two conduits (a 4″ and a 2″ run of schedule 80 conduits) from the base of our tower to our shack. These conduits will carry coax feed lines and control cables to our new tower. We used a pair of 22° elbows to create a smooth transition to bring the conduits out of the ground. This will ensure that our hardline and other coax cables can be placed in the conduits without creating excessive bends.

Conduits will fill with water even if they are sealed. This happens as a result of the condensation of water in the air. To prevent our conduits from filling with water, we created two drain pits at the bottom of the trench at the two lowest spots in the conduit runs and filled them with stone. We drilled a few holes in the bottom of the conduits above the drain pits to allow the water to drain so our cables will remain dry.

EME Tower

Cadweld’ed Ground Cable Bonded to a Ground Rod

We also created a bonding ground cable run from our new tower to the ground system at our shack entry. The bonding system was created by driving an 8′ ground rod every 10′ in the trench between our new tower and the perimeter ground around our house.

#2 stranded copper ground cable was Cadweld’ed to each ground rod to create a ground path to bond the tower to the perimeter grounding system around our house. Using a Cadweld system is simple and produces strong connections that will not deteriorate.

Here’s a video that shows our a Cadweld is made. We’ll cover completing the ground connections to the tower and the perimeter grounding system in a future article.

EME Tower

Completed Footings – Ready to Pour Cement

Finally, we used some sections of rebar to firmly support the guy anchor rods prior to pouring the cement. If you look closely, you can see a portion of the rebar material in one of the guy anchor footings in the photo above.

EME Tower

Cement Mixer

The next step in this part of our project was to pour the cement. A large cement mixer brought the proper cement mix to our QTH and Matt used his tractor to transport the cement from the mixer to the forms. We did a bit of finishing work on the cement base for our tower and let the cement dry for a few days.

EME Tower

FInished Tower Base and Cable Conduits

The last step was to remove the forms and backfill the footings. A little work with a cement finishing block was done on the cement base to round off the rough edges left by the forms. The cable conduits emerge from the ground next to the tower base. You can also see one end of the copper bonding cable next to the conduits as well.

EME Tower

Completed Guy Anchor

Here’s one of the completed guy anchor rods after backfilling. We are going to let the cement harden for a couple of weeks and then we’ll complete the construction of our new tower.

Here are some links to other articles in our series about our EME Station 2.0 project:

If you’d like to learn more about How To Get Started in EME, check out the Nashua Area Radio Society Teach Night on this topic. You can find the EME Tech Night here.

Fred, AB1OC

New 70cm Yagi

M2 Antenna Systems 432-9WLA Specifications

M2 Antenna Systems 432-9WLA Specifications

We decided to replace our current 70cm yagi with a newer, higher performance one from M2 Antenna Systems. We choose the M2 432-9WLA. The new antenna has higher gain and a cleaner pattern than our current 70cm yagi. It also has a longer boom.

New Yagi Ready For Installation

New Yagi Ready For Installation

The first step in the project was to assemble the antenna and check its SWR on the ground. The elements on an antenna like this typically vary by small amounts and are usually not arranged from shortest to longest. It is important to carefully measure each element during installation to confirm that each element is installed at the correct location on the boom.

The folks at M2 Antenna Systems made up a custom boom support truss for us. This is important given the potential for ice and snow accumulation that we face here in New England. We also made up a section of LMR-600uF coax to connect the antenna to the feedline and preamp system on our tower.

Driven Element Details

Driven Element Details

The new antenna uses a Folded Dipole style feed point. This system is essentially a T-matching arrangement where the two sides of the driven element are fed 180 degrees out of phase. It is important to set the locations of the shorting blocks carefully to ensure proper operation of the driven element and a resulting low SWR.

Yagi Going Up The Tower

Yagi Going Up The Tower

Matt, KC1XX, and Andrew from XXTowers handled the installation of the new Yagi on our tower. The installation involved climbing our 100 ft tower and the 25 ft mast at the top to remove the old yagi and install the new one. Note the careful rigging of the new antenna and associated feedline. This allows the new antenna to be pulled up the tower without damaging it.

Climbing a mast is not for the faint at heart! An installation like this one is clearly a job for experienced professionals. Andrew makes this task look easy. Our tower camera captured some video (click on the image above to play) of Andrew’s handy work.

Completed Installation

Completed Installation

The new yagi (top antenna in the picture above) is installed on a 5 ft fiberglass mast extension. The extension is used to ensure that the antenna does not “see” a metal mast which would disrupt the antenna’s pattern. The final installed height of our new yagi is a little over 125 ft. Note Andrew’s good work in attaching the feedline to the mast.

432-9WLA Installed SDR - Shack End

432-9WLA Installed SDR – Shack End

With the new yagi installed and hooked up, we made a final check of the end-to-end SWR from the shack. The antenna’s SWR is very good and the 2:1 SWR bandwidth extends from the bottom of the 70cm band to almost 450 Mhz. The new antenna is optimized for weak signal work up through the ATV sub-band and its SWR is below 1.2:1 in this range.

Fred, AB1OC