Dipole	Goal!

I updated the rotor with a Quick-Connect kit from C.A.T.S. This kit does away with the crappie screw type connector found on older Hygain/CDE rotors. While I had the rotor apart I discovered that all of the bearings in the lower race are rusty.  So,  I ordered and installed new ball bearings and low temp grease from CATS.   

I also built the EZ rotor kit from Idiom Press  it’s a Hygain DCU-1 compatible RS232 computer interface. This kit puts a brain in the rotor controller. For manual control all I have to do it turn the calibration  to the heading then press and release the brake leaver, the controller does the rest for me. Most logging programs will automatically set the rotor to the correct heading via RS-232 port on the EZ rotor interface.  I used heavy duty  (2)16 and (6)18 gauge Belden  type 9405 wire for my rotor control. 

Ok, I got my new tower in the ground and up in the air 55 feet 4 inches. If all goes as planed, the Mosley will be up this summer. I buried a 3-inch Schedule 40 PVC pipe to feed the coax feed lines from the tower to the shack This should keep the wires safe and out of site.  I poured 23 bags of 80 lbs concrete for the tower base. The base is 6 feet deep with a load of rebar.

What a workout! I planted 3 each, 4 inch Schedule 40 galvanized pipes for the guy wires. They have a big hunk of 1-inch metal welded to the bottoms of them. I think these were used as road sign pole. I poured 5 Bags of 80 Lbs concrete into each Guy pole hole. I have 3 sets of guy wires 3/16 EHS at 30 and 50 feet up the tower. I used the Rohn guy brackets to mount the cables to the tower and thimbles and cable clamps to terminate the ends. I installed safety hoops above each turnbuckles through the thimbles, eyebolt and around the pipe. This is just in case a turnbuckle fails.

I pounded 3 ground rods for grounding each tower leg at the base. I built a tool to make this job easier. It is a piece of black gas pipe with a water hose fitting on one end and a nipple on the other. I hook it up to the hose and push it into the ground four feet then a drive the ground rod into the hole. This tool is a great time and spine saver too.

I have finished cleaning the Mosley TA33 and 40 meter option. I used steel wood and polishing wheel to get the job done. I removed the undersize bolts from the mast bracket and replaced them with grade-8 5/8th bolts.  I used anti-corrosion grease from Mosley between all the telescoping parts. I cleaned and inspected the traps. I replaced the worn out screws with stainless steel allens. Many of the woodscrews were loose, I replaced those with new larger stainless steel screws. As soon as I can I will paint the antenna with weather guard so that the antenna will stay shiny longer.  I installed the missing parts for the 40 meter option and all new plastic caps for the elements. I replaced the bent section with one that I ordered Mosley. Oh my, this antenna is big! I'm going to need lots of help putting this monster on the top of the tower. 

I installed the Phillystrand for use as guys for the 40 meter elements, I also installed new thimbles as the old ones were rusted. I also ran extra guys to support the main boom.

My brand new TB3 thrust bearing kept binding when tried to turn it. I guess "they" don't make em like the used too.

So,  I had to fix it.  Click here for more details .

Yet, more setbacks. I climbed the tower to remove the lighted star I had place there for Christmas and to remove the old rotor plate. The bolts for the rotor plate were rusted so bad I had to cut them off. I will replace them with stainless steel. While I was up there I noticed that there is not a way to install the Tailtwister II rotor anywhere but the very top (where I intended to install the thrust bearing). Hmm, I could remove the upper guy wires and pull the top off, then install the rotor. (don't like that idea at all).  Or, I could cut the lower horizontal brace. I really don't like either of these plans. I could cut one weld and weld it back with a small 110 Volt mig welder. I don't want to have compressed Co2 gas hanging 55 feet in the air. If I go this route I will use flux wire and clean up the slag and paint some cold Galvanizing over the weld. I will have to stew on this one for a while...

I found this stuff called Cold Galvanizing spray. It's made by LPS. It's made with 95% zinc. I am using it on the mast pipe and anything else that is unprotected steel.

As an experiment, I selected the Steel bracket that holds the mast pipe to the rotor. It was completely rusted. I cleaned the rust off and painted 4 thin coats of Cold Galvanizing on the clean steal. I then baked it in the oven  for 1 hour at 350 degrees F. The surface is now hard has stone. Very cool stuff. It's not cheap. ACE Hardware was sell it at about 10.00 per can.    

I fished the hardline through the 3 inch PVC that I had buried. I now wish I had used 4 inch line. Oh will too late now. What a pain the the butt! Good thing I put some 550 cord inside the pipe. 

I have decided to take the top guy off, then take top section off of the tower and then install the rotor inside the tower. I will also add one more 10 feet section to the tower. What the heck I have the thing apart, lets do it. This will put me at 65' 4" at the top of the tower. I also bought some brackets at a hamfest that will allow me to add side arm mounts to the tower. I plan on hanging some VHF/UHF antennas on the side of the tower.

A good friend come over to the house and installed the N connectors on the  ½ inch Andrews LDF4-50A hardline. He had this very cool prep tool that made the job look easy. I got to get one of those tools. Very cool... I guess it's time to surf EBay.

I have decided  to install another 10 foot section to the tower.  I will need to remove the top guys and guy bracket and then remove the top section. Install the additional 10 foot section and then install rotor, thrust bearing, mast. in the top section, Install the top section, reattach guy brackets and guys. Sounds like another weekend project!

I picked up up 3 more ground rods and 35 feet of copper ground wire to used for the grounds on the guy wires. I hope to get these installed soon.  I also trimmed the trees to that I can fly the antenna up the tower. I raised the bean up to about 7 feet on the tripod. I also tested the antenna with my MFJ antenna analyzer. the VSWR looks good on all bands! The bandwidth for 40 meters is tight but it is great in the voice portion of the band. 

Over the summer I installed 1 each ground rod and wire for each sets of guy wires and clamped a heavy copper wire from each guy wire to the ground rod.

I Removed top section and top guys and Installed another 10 foot section and reinstalled the top section with rotor, assy plate, TB3 and newly drilled assy plate and mast pipe. A few weeks later I installed the antenna.

I modified the RCS-8V Antenna switch by replacing the UHF So231 connectors with "N" type connectors. This way the "N" connectors on the 1/2" hardline will not need any adaptors. I used a double shielded silver coax for the feed line from the switch to the beam. I think it was used in a microwave application of some sort.

Well, She's 65 feet in the air!