1^st time it was up.

When the mast is completed you will have a 20’ mast guyed at its top and midsection in 3 directions. It will be capable of supporting a lightweight antenna such as a J-pole, small beam or solid dipole. It’s not designed to withstand a lot of wind or large antennas.

You’re more than welcome to make it taller, but it’s not recommended.

3 male 1 ½" threaded couplings

3 female 1 ½" threaded couplings

1 1½" tee

1 1½" to 1" reducer (glue on)

1 1" Pipe cap(female threads)

Small can of PVC cement

2 100’ length coils of clothesline rope or equivalent

3 large stakes for guy ropes

2 plastic or aluminum guy plates (see note)

NOTE: Guy brackets are recommended for use of a small directional antenna to ease in turning mast to aim antenna. If not used, then you must tie guy ropes directly to mast. Pictures are later in article.

If you decide to use the brackets then the following materials are required:

1. 5 5/8" by 5 5/8" by 3/16" aluminum plates

Recommended tools:

Hacksaw

Tape measure

Knife

Cigarette Lighter (fuse the end of your guy ropes if synthetic rope)

Hammer; maul; rock; club( somethin’ to drive guy stakes with) We used RxR track.

Any other tools you may need to mount the antenna

If you decide to use the brackets then the following are required:

2" hole saw

3/8s drill bit

Drill

De-burring tool, sandpaper, file or dremel tool to smooth edges

Bench vise and hammer. Or some means of bending metal.

Cut both pieces of PVC pipe exactly in half. (There is still one more cut to be made, more on this later)

There is some counsel necessary when it comes to working with PVC cement. Heed the advice from those who have screwed up and had to buy new parts. Not to mention any names….

Once the PVC cement is applied it will start to set in approx. 10 seconds and WILL be set in approx. 15 seconds. This may not sound like much time, but it is sufficient as long as you planned properly. The 7 P’s= Prior Proper Planning Prevents Pi$$ Poor Performance. Read the instructions on the can of cement that you plan to use. Different manufacturers have different recommendations.

Make sure to keep cement off from all threaded surfaces and anything that you don’t want glued. Once glue is applied it is PERMANENT.

This is the pictorial procedure for gluing all PVC pipe, couplings, fittings etc. regardless of the application. The steps in constructing the mast follow.

Apply glue to pipe Apply glue to coupling

NOW VERY QUICKLY

Twist coupling onto pipe Hit it with your hand to seat coupling

Now, let’s look at the mast laid out on the floor, loosely assembled. Just so you get the overall picture of the final product.

Bottom showing "T" fitting Mid- section showing guy bracket

Top w/ guy bracket & reducers View from top to bottom

Lay your parts out on a flat surface. Starting from the top and going to the bottom they must be in this order.

• 1" plastic pipe cap
• 1" pipe nipple (6" long)
• 1" to 1 ½" reducers
• Guy bracket
• 1 ½" threaded female coupling
• 5’ pipe
• 1 ½’ threaded female coupling
• 1 ½ threaded male coupling
• 5’ pipe
• 1 ½" female coupling
• Guy bracket
• 1 ½" threaded male coupling
• 5’ pipe
• 1 ½ threaded female coupling
• 1 ½" threaded male coupling
• 5’ pipe (Here’s the "extra cut" we mentioned). Cut 3 ½ inches off the bottom most end. This keeps ALL parts the same length for packing & transport. Finally:
• 1 ½" TEE

Exploded view of top

Assembled joint

Male threads should be facing UP whenever possible to prevent water from getting into the threads and possibly freezing. Shown in "Assembled joint" picture.

The purpose of the Tee joint is to allow coax to run down the interior of the pipe and surface at the bottom without the weight of the mast sitting on it.

The reduction to 1" pipe at the top is to allow a small beam to be mounted with the use of standard "U-bolts". The reducers that we used were locally available to us. Due to your location specifications may vary, but you get the idea.

When all of the cuttin’ & gluin’s done, here’s what you should have:

WHA-LAA!!!!!!!

One last item to manufacture…da guy ropes. You will need 3 sections of rope cut 30’ long for the top guys. You will need 3 sections of rope cut 25’ long for the mid guys. Tie the guys directly to the mast or to the guy brackets if used.

Guy ropes on bracket Close-up of the same

Now, let’s erect this puppy!!!!

This takes at least 2 people to erect. 3 would be ideal. Find a clear flat area approximately 35’ in diameter. Decide where you want the mast to set. Measure out by the following approximate dimensions and set 3 guy stakes/anchor pin.

Where guy placements should go

Measure approx 16’ out from where the bottom of the mast will be in 120 degree intervals.

Mast ready to go up

JW tryin’ to look busy!

1 person pushes the mast toward the 3^rd stake and pushes upwards at the same time using the 2 guy ropes that have been tied off at support for the top of the mast. Don’t try and tip this thing up. You NEED to use the 2 guys to your advantage. If you just try and tip it up, it will break!!

During the "standing up process" the mast will flex. It’s only PVC pipe. A little flex is ok, just ensure that it doesn’t start looking like a fishing pole with a 15 lb fish on it and you should be fine.

JW and I set this up in 15 minutes on my front lawn

See the J-pole "copper cactus" in the top?

Coax coming out of the Tee joint

We know you can buy a collapsible 35’ mast at Radio Slack all pre-assembled for about $35-40 bux, BUT can you fit that in a small vehicle?….didn’t think so. Being only 5’ long this will fit in just about any trunk! :o)

Well, that’s pretty much all there is to it. Get creative and paint it. Cammo would be cool! Again don’t overload it and try to stick a HF beam on top or try and use it during a hurricane. Common sense prevails. Have fun & happy HAMMING!!

Be safe and stuff.
Eli & JW

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