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
Framing square
Ruler, one foot long, divided into tenths of an inch or in millimeters
Drill press
Drill bit nine sixty-fourths (0.140) inches diameter; another bit about half that diameter for pilot holes
Center punch
Screwdriver, for 6-32 screw head
Wrenches, two, for 6-32 nut
Medium-width permanent marker
Extremely innovative! Love the use of the copper tubing. Seems really well thought out and with an eye toward quality construction. <br>2 QUESTIONS: <br> <br>1) have there been any simulations done on this methodology (nec).as far as gain, etc. and are the data available? <br> <br>2) using the nikiml models (to make a GH2n2 or n3), do I make the tubing lengths to the same size as specified by nikiml for the #6 wire, or are their any modifications to make for the tubing element?
PenJet, when I built my most recent antenna, which I call GH10n3 SNAP, I developed a way to make the active elements from copper tubing without the need to build a jig. I used the antenna's plastic tubing frame as the assembly jig. The same method shouId work with any model GH. I have not created an Instructable about how to do it, but I included a long photo caption describing the procedure in a photo album at digitalhome.ca. The link to that album is http://www.digitalhome.ca/forum/album.php?albumid=1050. Click the photo to see the caption. <br>unclesam
PenJet, do note that I have posted several other Instructables about the construction of GH antenna active elements using prepared links of copper tubing. Your Q: 1) nikiml has been asked many times whether using copper tubing instead of solid #6 copper wire or instead of 1/4-inch outside dia aluminum rod or tubing (specified for his more recent antenna designs), makes any difference, including again just recently. His answer: the difference is negligible. <br>2) Before I pursued the use of links of copper tubing with their ends flattened, I asked at the digitalhome.ca forum whether flattening the ends would make any difference, was told it would not, that no compensation in dimensions was needed. There is a difference in the lengths of the tubing lengths versus the specified lengths for #6 wire. However, note that the lengths in both cases are to be measured at the CENTERLINES of each. Therefore, the lengths specified by nikiml for a #6 wire length would fall at the centerlines of the holes drilled at the ends of my tubing lengths. You need to cut the tubing lengths longer than that in order to create the flat pads that are drilled and are soldered together. My other Instructables about building the active elements show the details. To find them, click on my username or enter unclesam into the search box on the Instructables home page. Scroll to find all applicable projects. <br>Hope this answers your questions, unclesam
Thanks for the excellent tutorial. <br> <br>You can and should delete all references to the GNU GPL as the Gray-Hoverman antenna &quot;designs&quot; are in the public domain. Copyrights and, thus, the GPL, do not apply to designs. <br> <br>You can, of course, apply the GPL to your photographs and text description if you like.
Thanks for the ible but could you make the legal story clearer?<br> <br> Step 2 says <em>&quot;The design (...) and its dimensions are protected under license (by others). This information is offered free for personal use, but no commercial exploitation is permitted.&quot;,&nbsp;</em>and step 9 shows us a GNU license.<br> <br> I believed the GNU license let you free to copy, but you had to distribute under GNU, that is you also could be copied.<br> <br> What exactly is copyright, is it design, dimensions or the clever tubing element?<br> <br> Have a nice day.<br> <br>
smessud, the design of the Gray-Hoverman antenna, including its specific dimensions, is covered by GNU (by others). Further information about that may be found at the links I provide in the final step at digitalhome.ca and to the GNU. I have nothing to do with the design of the antenna. <br> My innovation is the construction of the antenna's active elements using links of copper tubing by the methods I include in my three Instructables. The dimensions are copyrighted, my method is not. The three Instructables are covered by the Instructables license, as seen on the INFO box to the right. More about that can be found at this website. <br> Bottom line, if you want to build yourself a Gray-Hoverman antenna, you are allowed to, and if you want to use my method to make the active elements, you may. That is my sole purpose for providing this information. If you have some other use in mind, you should address your questions to either Digitalhome.ca or Instructables.com, whichever applies. My interest is not in the legal issues, it is in sharing how to build things with other like-minded people. <br>Unclesam

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