Step 1: My Other Gray-Hoverman TV Antenna Instuctables
b. Make The Active Elements:
Build the assembly jig:
Prepare the copper tubing links:
Assemble the active element:
c. Antenna Plastic Frame Assembly:
d. Reflector Rods:
e. Straighten Copper Wire:
f. Make tophat (alternative to straight) NARODs:
Step 2: Materials and Tools
Plastic antenna framework: see Instructables
Plastic Craft, Framework Assembly
Antenna active elements: see three Instructables
NARODs (optional), 2, # 10 solid copper wire, cut to length to optimize VHF-high station most of interest--see pdf antenna drawing
Reflector rods, six for UHF-only, eight for UHF and VHF-high, see Instructable Reflector Rods
Supports for the two active elements, 5, T-shaped, assembled from marked CPVC pipe and tees, dimensions depending upon the antenna version being built. Drill holes that will accept #6 screws only in the two ends of the support that will be the signal pickoff points for the antenna, drill all the way through, the spacing determined by the antenna drawing. Holes for the others will be drilled in place to fit the elements.
Element and NAROD supports, 8, made from modified 1/2-inch CPVC elbow and with 1/2-inch CPVC pipe cut 3 1/2 inches long, see Instructables Plastic Craft
NAROD end supports, 4, 1/2-inch CPVC pipe cut to 3 1/2 inches long, one quarter-inch diameter hole drilled through one end, see Instructables Plastic Craft
Pipe cap, 4, 1/2-inch CPVC, hole drilled into only one side, to pass # 10 wire
Brass screws, 16, 3/8-inch long, #6, nuts and bronze lock washers
Brass screws, 2, 1-inch long, #6, 6 nuts and 3 bronze lock washers
Nutdriver or adjustable wrench
Primer for cementing PVC plastic plumbing pipe and fittings
All-in-one cement for PVC and CPVC plastic plumbing pipe and fittings
Q-tips for applying plastic primer and cement
PVC tee, 2, 1-inch by 1-1/4 inch. Temporarily slipped over the ends of the lower of the two crosswise horizontal element and NAROD support tubes, to form feet that, along with the bottom bell of the lower 1-inch PVC cross fitting, can support the antenna upright on a workbench as it is being assembled.
Step 3: Insert NAROD Supports and the NARODs
Insert NAROD supports, and the NAROD end supports, into their holes in the crosswise horizontal tubes of the antenna plastic frame, but do not glue them at this time. See Plastic Craft for how to glue them in place when the time comes.
Slide in the NARODs and install the drilled pipe caps to capture them on the ends of the NAROD end supports, taking care no to bend the NARODs. (This arrangement is obviously overkill for supporting straight NARODs, however I wanted to be able to also support the optional "tophat" NARODs, for experiments. See Plastic Crafts Instructable for details).
Step 4: Install Element Supports
Step 5: Install Active Elements
A second attachment method that I used in a more recent antenna, is to use copper pop rivets and copper backup washers, see the composite photo. The pop rivets were ordered from Best Materials website, box of 100. The copper washers were found at TruValue hardware store, sold as "burrs" for use with conventional copper rivets used in leatherworking. I pre-curved the washers by hammering them around a steel rod. The signal pickoff included brass nuts soldered to the appropriate corners of the active elements during their assambly. Brass screws, inserted from the backside, secure those two corners to the frame. The wire lugs from the balun are connected using bronze lock washers and a second brass nut.
Step 6: Cement the NAROD Supports
Step 7: Insert the Reflector Rods
The 6 (or 8 if NARODs are used) reflector rods are installed within 5-inch lengths of 1/2-inch CPVC pipe, their lengths, and the gap between their ends, according to the antenna drawing. The CPVC pipes are given marks that make it possible to show that they are centered within the antenna's spine while they are being cemented. Cement the rods in place, making sure that the different lengths are in the correct locations. PEX is easily damaged by sunlight. If the antenna is to be mounted outdoors, drill a 3/8-inch diameter hole through the centers of 1/2-inch CPVC pipe caps and glue one to each end of each reflector CPVC pipe once the reflectors are installed in the antenna.
Step 8: Attach Antenna to Mast
Step 9: Antenna Information Links
2. Antenna Research and Development Forum
3. Link to the license: