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This is how I assemble the zigzag active elements for a Gray-Hoverman tv antenna from prepared quarter-inch outside diameter copper tubing links. The links are placed on an assembly jig and soldered together. Copper elements used on indoor antennas can be attached using plastic screws. Plastic will not stand up outdoors, so elements used on outdoor antennas should be attached with metal: copper (best) or brass (commonly available) screws, washers and nuts will minimize corrosion. This is one of three Instructables that describe my method for producing consistent, quality elements that are lightweight, durable, have the desirable sharp corners and have holes for mounting the elements to the antenna's framework. To see the other two, one how to build the needed assembly jig, one detailing preparation of the links, and my other 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 in the INFO box.
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Signing UpStep 1Tools and Materials
Gray Hoverman TV Antenna Active Element Assembly Jig (homemade, subject of another Instructable)
8 Gray Hoverman TV Antenna Active Element Copper Links (homemade, subject of another Instructable. Those made from thickwall tubing will yield a zigzag weighing about 153 grams [5.3 oz], from thinwall tubing 113 grams [4 oz])
Steel wool for cleaning copper
Electric soldering iron or gun, heavy duty
Miniature gas torch, Bernzomatic (optional, but you know you want one)
9 number 6 flat washers
9 6-32 hex nuts (optional, for clamping the joints together while soldering, if you have the miniature torch. Now you have an excuse to go buy one)
Solder suitable for copper, plumbing or electrical type
Soldering paste (flux), plumbing, such as Nokorode
Brush for applying soldering paste
Solder flux remover, commercial (or a 50-50 mixture of mineral spirits [aka paint thinner] and rubbing alcohol--observe all safety precautions for the two chemicals)
Stiff brush for cleaning off flux
Paper towels for mopping flux remover from soldered joints
Bench vise
Pliers, combination
Screwdriver, small, for 6-32 screw head
Wrench for 6-32 nut
8 Gray Hoverman TV Antenna Active Element Copper Links (homemade, subject of another Instructable. Those made from thickwall tubing will yield a zigzag weighing about 153 grams [5.3 oz], from thinwall tubing 113 grams [4 oz])
Steel wool for cleaning copper
Electric soldering iron or gun, heavy duty
Miniature gas torch, Bernzomatic (optional, but you know you want one)
9 number 6 flat washers
9 6-32 hex nuts (optional, for clamping the joints together while soldering, if you have the miniature torch. Now you have an excuse to go buy one)
Solder suitable for copper, plumbing or electrical type
Soldering paste (flux), plumbing, such as Nokorode
Brush for applying soldering paste
Solder flux remover, commercial (or a 50-50 mixture of mineral spirits [aka paint thinner] and rubbing alcohol--observe all safety precautions for the two chemicals)
Stiff brush for cleaning off flux
Paper towels for mopping flux remover from soldered joints
Bench vise
Pliers, combination
Screwdriver, small, for 6-32 screw head
Wrench for 6-32 nut
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