This jig makes it easy to form the zigzag active elements needed for every version of the Gray-Hoverman tv antenna, using prepared links of common quarter-inch diameter copper tubing. The time and effort needed to make the jig will pay off in the quality and consistency of the elements produced, and the jig can be used many times if friends or neighbors also want to build their own antennas. My method produces elements that are durable, lightweight, have the desirable sharp corners and have holes for mounting the elements to the antenna's framework. This is one of three Instructables about making the active elements. To see the other two and my related Instructables, click on unclesam in the INFO box to the right, then repeatedly click NEXT to page through them all. To receive automatic notice when I post future Instuctables about my method for assembling the entire outdoor antenna, members can click to subscribe to me.
Step 1: Materials and Tools
Base: particle board or plywood, flat, 12 inches by 32 inches, one half to three quarters of an inch thick; edges do not need to be perfectly straight or smooth, nor the corners perfectly square.
Screw Posts: nine 6-32 screws, one and one-half inches long; twenty-seven 6-32 nuts; eighteen number six flat washers.
Drawing paper 12 inches by 32 inches (Optional) You can also draw directly on the base board, but paper will allow greater precision.
Drawing compass(es), having hard, very sharp pencil lead or dividers having very sharp points; capable of drawing arcs up to 7.07 inches (180 mm) radius, such as Dasco Pro, Inc., Giant Circle 12-inch Beam Compass shown in photo.
Pencil having hard, very fine point
Straight edge, such as yardstick, metal version preferred
Ruler, one foot long, divided into tenths of an inch or in millimeters
Drill bit nine sixty-fourths (0.140) inches diameter; another bit about half that diameter for pilot holes
Screwdriver, for 6-32 screw head
Wrenches, two, for 6-32 nut
Medium-width permanent marker