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This is how I prepare quarter-inch outside diameter copper tubing links that form the zigzag active elements for a Gray-Hoverman tv antenna. 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 the final element assembly, 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
Materials
copper tubing, one quarter-inch outside diameter, five feet long for each zigzag (includes plenty for cutting waste). Two zigzags required for each antenna, two required for each bay of a multibay antenna). Choose thickwall or thinwall, as discussed below
Tools
Gray Hoverman TV Antenna Assembly Jig, subject of another Instructable
Tubing cutter, wheel type for the thickwall tubing or tiny hacksaw for thinwall
Tubing flaring tool, or something similar, for gripping tubing without damage while cutting it
Bench vise
Combination pliers, large
Scribe or scratch awl, metal, sharp
Flat plank for rolling links straight
Ruler, one foot, divided into tenths of an inch
Dividers or beam compass capable of transferring measurements up to 8 inches
Tin snips
Flat files, coarse to fine
Rattail file, round, that will fit into end of tubing for deburring cut ends
Electric drill or drill press, and bit nine sixty-fourths (0.140) inch diameter, plus bit about half that diameter for pilot hole
Needle file, round, that will fit inside a hole 0.140 diameter
Tape, masking or painter's
Medium point permanent marker
copper tubing, one quarter-inch outside diameter, five feet long for each zigzag (includes plenty for cutting waste). Two zigzags required for each antenna, two required for each bay of a multibay antenna). Choose thickwall or thinwall, as discussed below
Tools
Gray Hoverman TV Antenna Assembly Jig, subject of another Instructable
Tubing cutter, wheel type for the thickwall tubing or tiny hacksaw for thinwall
Tubing flaring tool, or something similar, for gripping tubing without damage while cutting it
Bench vise
Combination pliers, large
Scribe or scratch awl, metal, sharp
Flat plank for rolling links straight
Ruler, one foot, divided into tenths of an inch
Dividers or beam compass capable of transferring measurements up to 8 inches
Tin snips
Flat files, coarse to fine
Rattail file, round, that will fit into end of tubing for deburring cut ends
Electric drill or drill press, and bit nine sixty-fourths (0.140) inch diameter, plus bit about half that diameter for pilot hole
Needle file, round, that will fit inside a hole 0.140 diameter
Tape, masking or painter's
Medium point permanent marker
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