Homebrew 6 Meter Yagi’s By Eric Smitt K9ES

Why Build an Antenna ??? Look at the cost of Commercial 6M Beams……. 6M Beams are not that hard to build Parts ARE available 6M Beams are not that large

Commercial Pricing ! Manufacturer Model Elem. Boom Gain Cost Cushcraft A503S 3 5’ 6” 8 dbi $139.95 A505S 5 12’ 10.5 dbi $199.95 A506S 6 20’ 11.6 dbi $399.95 Hygain (MFJ) VB64DX 4 8.2 dbd $144.95 VB66DX 24’ 10.3 dbd $265.95 M-Squared 6M-3 6’ 9” 6.4 dbd $179.99 6M-5XHP 18’ 9.5 dbd $366.99 6M-7JHV 7 30’ 8” 10.9 dbd $389.99 Mosely AM-56 10.8 dbi $455.99

Commercial Designs – Cushcraft A505S

Commercial Designs – Cushcraft A506S

Commercial Designs – Hygain VB46DX

Commercial Designs – Hygain VB66DX

Very Large Commercial Yagis

Aluminum Tubing

Aluminum Tubing Part # Part Name Price DXE-AT1189 Aluminum Tubing 6' x 0.375" x 0.058" wall, 6063-T832 drawn, no slits $ 2.95 DXE-AT1480 Aluminum Tubing 6' x 0.500" x 0.058" wall, 6063-T832 drawn, no slits $ 4.15 DXE-AT1481 Aluminum Tubing 6' x 0.625" x 0.058" wall, 6063-T832 drawn, no slits $ 4.75 DXE-AT1482 Aluminum Tubing 6' x 0.750" x 0.058" wall, 6063-T832 drawn, no slits $ 5.35 DXE-AT1483 Aluminum Tubing 6' x 0.875" x 0.058" wall, 6063-T832 drawn, no slits $ 5.65 DXE-AT1484 Aluminum Tubing 6' x 1.000" x 0.058" wall, 6063-T832 drawn, no slits $ 5.95 DXE-AT1485 Aluminum Tubing 6' x 1.125" x 0.058" wall, 6063-T832 drawn, no slits $ 6.55 DXE-AT1486 Aluminum Tubing 6' x 1.250" x 0.058" wall, 6063-T832 drawn, no slits $ 7.75 DXE-AT1487 Aluminum Tubing 6' x 1.375" x 0.058" wall, 6063-T832 drawn, no slits $ 8.45 DXE-AT1488 Aluminum Tubing 6' x 1.500" x 0.058" wall, 6063-T832 drawn, no slits $ 8.95 DXE-AT1489 Aluminum Tubing 6' x 1.625" x 0.058" wall, 6063-T832 drawn, no slits $ 9.75 DXE-AT1490 Aluminum Tubing 6' x 1.750" x 0.058" wall, 6063-T832 drawn, no slits $ 10.65 DXE-AT1491 Aluminum Tubing 6' x 1.875" x 0.058" wall, 6063-T832 drawn, no slits $ 11.55 DXE-AT1492 Aluminum Tubing 6' x 2.000" x 0.058" wall, 6063-T832 drawn, no slits $ 12.45 DXE-AT1493 Aluminum Tubing 6' x 2.125" x 0.058" wall, 6063-T832 drawn, no slits $ 13.35 DX Engineering Aluminum Tubing Type 6063 - 6 ft. unslit ends New - DX Engineering Type 6063-T832 drawn - not extruded - aluminum tubing in telescoping 6 foot lengths.. HIGH STRENGTH TELESCOPING ALUMINUM TUBING Rugged aluminum alloy 6063 is most commonly used for seamless structural tube and pipe. It is popular in structural use for both its high strength and great, long lasting appearance.

Aluminum Tubing Part # Description Price Per Foot AL24-375 Cycle 24 PO Box 2233 Harrison, AR 72602 (870) 743-4027 (870) 743-4027 (870) 715-8228 (870) 715-8228 Fax: (870) 743-4023 sales@cycle-24.com Part # Description Price Per Foot AL24-375 Aluminum Tubing 0.375" OD x 0.058" wall, 6063-T832 $.50 AL24-500 Aluminum Tubing 0.500" OD x 0.058 wall", 6063-T832 $.70 AL24-625 Aluminum Tubing 0.625" OD x 0.058 wall", 6063-T832 $.80 AL24-750 Aluminum Tubing 0.750" OD x 0.058" wall, 6063-T832 $.90 AL24-875 Aluminum Tubing 0.875" OD x 0.058" wall, 6063-T832 $.95 AL24-1000 Aluminum Tubing 1.000" OD x 0.058" wall, 6063-T832 $1.00 AL24-1125 Aluminum Tubing 1.125" OD x 0.058" wall, 6063-T832 $1.10 AL24-1250 Aluminum Tubing 1.250" OD x 0.058" wall, 6063-T832 $1.30 AL24-1375 Aluminum Tubing 1.375" OD x 0.058" wall, 6063-T832 $1.40 AL24-1500 Aluminum Tubing 1.500" OD x 0.058" wall, 6063-T832 $1.50 AL24-2 Aluminum Tubing 2" OD x 0.058" wall, 6063-T832 $2.25

U-Bolts and Saddle Clamps Cycle 24 PO Box 2233 Harrison, AR 72602 (870) 743-4027 (870) 743-4027 (870) 715-8228 (870) 715-8228 Fax: (870) 743-4023 sales@cycle-24.com U-Bolts and Saddle Clamps

U-Bolts and Saddle Clamps Cycle 24 PO Box 2233 Harrison, AR 72602 (870) 743-4027 (870) 743-4027 (870) 715-8228 (870) 715-8228 Fax: (870) 743-4023 sales@cycle-24.com FOR TUBING SIZE Part# A B C D E F G H GA COMPLETE CLAMP U BOLT AND NUTS ONLY 1 1/4" **** CL113 2.31 1.63 2.30 1.00 1.36 0.26 0.93 .560 13ga $1.50 $.75 1 3/8" CL125 2.44 1.75 2.39 1.48 0.99 $1.60 $.80 1 1/2" CL1375 2.56 1.88 2.54 1.61 1.05 11ga $2.20 $1.10 2" Stainless CL2000 CL2000SS 3.25 2.50 4.00 1.50 2.17 0.31 .31 1.42 .640 3/8" $2.75 $8.75 $1.35 $4.50 2 1/4" CL2250 3.50 2.75 4.12 2.42 0.32 1.55 $3.00 2 1/2" CL2500 3.75 3.00 4.38 2.67 0.33 1.68 $3.25 3" CL3000 4.87 3.17 0.30 1.90 .82 $2.25 3 1/2" CL3500 4.88 5.37 3.67 0.56 2.40 .820 $5.00 $2.50 **** (For tubing sizes 1 1/4, 1 3/8, and 1 1/2) U-Bolt - 5/16-18 UNC-2A Threads Nuts – Serrated Flanged For tubing sizes 2" through 3 ½" U-Bolt -- 3/8-16 UNC-2A Threads Nuts - Serrated Flanged All Clamps are Zinc Plated with Yellow Dichromate Dip

U-Bolts and Saddle Clamps DX Engineering U-Bolt Saddle Clamps Our U-bolt saddle clamps are designed specifically for antennas: First, they're made in sizes that fit tubing--not pipe sizes like the clamps that you might be able to purchase at the hardware store. Second, the U-bolts that come with them are made of high-strength 18-8 stainless steel, and they're long enough to attach tubing to thick plates. In addition to 5/16’’ U-bolts in the 2, 2.5 and 3’’ clamps we have recently added 3/8’’ U-bolts in the same sizes. See Clamp Dimensions below. Part # Part Name Price DXE-SAD-050A 1/2 in. Saddle Clamp, Stainless 1/4 in. U-Bolt & Hardware $ 4.95 DXE-SAD-075A 3/4 in. Saddle Clamp, Stainless 1/4 in. U-Bolt & Hardware $ 5.35 DXE-SAD-100A 1 in. Saddle Clamp, Stainless 1/4 in. U-Bolt & Hardware $ 5.70 DXE-SAD-125A 1-1/4 in. Saddle Clamp, Stainless 1/4 in. U-Bolt & Hardware $ 6.55 DXE-SAD-150A 1-1/2 in. Saddle Clamp, Stainless 1/4 in. U-Bolt & Hardware $ 7.40 DXE-SAD-175A 1-3/4 in. Saddle Clamp, Stainless 1/4 in. U-Bolt & Hardware $ 8.55 DXE-SAD-200A 2 in. Saddle Clamp, Stainless 5/16 in. U-Bolt & Hardware $ 9.75 DXE-SAD-200B 2 in. Saddle Clamp, Stainless 3/8 in. U-bolt & Hardware $ 10.95

U-Bolts and Saddle Clamps DX Engineering V-Bolt Saddle Clamps The saddles are sold as a set and not as individual components, however you may order additional or replacement “V” bolt hardware sets. Part # Part Name Price DXE-CAVS-1P V-Saddle Clamp, 1/2 in. to 1-3/4 in. O.D. Applications $ 9.95 DXE-CAVS-11P V-Saddle Clamp, 1/2 to 1-3/4 in. O.D. Applications, 5/16-18 thread $ 10.45 DXE-CAVS-2P V-saddle clamp, 1 to 2 in. O.D. Applications $ 11.95 DXE-CAVS-3P V-Saddle Clamp, 2 in. to 3 in. O.D. Applications $ 14.95

U-Bolts and Saddle Clamps DX Engineering Powder Coated Saddle Clamps Our powder coated saddle clamps are made in sizes that fit tubing--not pipe sizes like the clamps that you might be able to purchase at the hardware or automotive sources. The U/V-bolts that come with them are made of high-strength 18-8 stainless steel, and they're long enough to attach our Multi-Purpose Mounting Plates to a variety of different roll cage or tubing diameters. These powder coated saddles are cast with high-strength 535.0 aluminum, which also has superior anti-corrosion properties, to grip the tubing securely. Unlike the stamped or machined type their as-cast rippled surface is the correct size to fit the tubing closely and will grip the aluminum tubing for a secure fit that resists the ravages of weather. The powder coated saddles are sold as a set and not as individual components, however you may order additional or replacement “U/V” bolts sets. Always use a lubricant such as Never-Seez to prevent the stainless steel hardware from seizing. Part # Part Name Price DXE-PCAVS-1P 1/2 in. to 1-3/4 in. O.D. Blk Powder Coated V-Saddle Clamp $ 10.90 DXE-PCAVS-2P 1 to 2 inch Powder Coated V-saddle Clamp, Black $ 12.95 DXE-PSAD-050A 1/2 in. Powder Coated Blk U-Bolt Saddle Clamp, Stainless 1/4 in. U-Bolt & Hardware $ 6.80 DXE-PSAD-075A 3/4 in. Powder Coated Blk U-Bolt Saddle Clamp, Stainless 1/4 in. U-Bolt & Hardware $ 7.10 DXE-PSAD-150A 1-1/2 in. Powder Coated Blk U-Bolt Saddle Clamp, Stainless 1/4 in. U-Bolt & Hardware $ 9.05 DXE-PSAD-175A 1-3/4 in. Powder Coated Blk U-Bolt Saddle Clamp, Stainless 1/4 in. U-Bolt & Hardware $ 10.15

Anti-Seizing Compound DX Engineering An Anti-seize compound MUST be used on any Stainless Steel nuts, bolts, clamps or other hardware to prevent galling and thread seizure. Any of these products can be used for this purpose. Part # Part Name Price *DXE-80078 ANTI SEIZE 8oz Brush Top Can $ 10.99 * This product is limited to domestic UPS Ground shipping only *DXE-81343 Anti-Seize, 1 oz. Squeeze Tube $ 2.99 *DXE-81464 Anti-Seize, 8.5 oz. Aerosol Can $ 12.99 *DXE-NSBT8 Never-Seez, 8 oz. Brush Top $ 12.95 *DXE-NMCBT8 Never-Seez, 8 oz. Brush Top, Mariner's Choice $ 14.95

Local Hardware + Surplus Stores Daytona Bolt and Nut Ace Hardware Tractor Supply Northern Tool Home Depot Lowes Travis Hardware Astro Too Skycraft (Orlando) Fastenall (Dow Road)

Inexpensive Element to Boom Mounting An Aluminum Plate (3” x6”) is drilled with 8 holes spaced for the different U-Bolts. The U-Bolts support the element and the boom. In this case, the element is electrically connected to the boom.

Inexpensive Boom to Mast Mounting A used Aluminum Panel is drilled and 2 DX Engineering Saddle Clamps are mounted to hold the boom. The panel will then be drilled to mount 2 additional Saddle Clamps to connect to the mast. This is a low cost solution to the $100 commercial units.

Inexpensive Direct Feed with Balun Split Driven Element with Fiberglass Insert Insulator Current Balun This is being used on my “Clone” HygaIn VB66-DX

Using Level to place elements Horizontal

Finished Beam is “Clone” Hygain VB66DX Boom is 24 Feet long, 2 inch diameter From old Hygain 204BA damaged yagi. Total cost was less than $30.00 for new U-Bolts. Element to Boom Plates were cut from old aluminum panel. Antenna element tubing was from old antennas. This antenna will be at 152 feet.

The Cushcraft A5S Gamma Match

Making a Gamma Match Feed Plexiglas Spacer Aluminum Strap

Making a Gamma Match Feed

Making a Gamma Match Feed SO-239

Tuning a Gamma Match with a Trimmer Capacitor 5-75 pfd Trimmer Capacitor Once the Trimmer Capacitor is set for Lowest SWR, it is removed and the capacitance is measured with the MFJ-269 unit.

Replace Trimmer with RG-213 Capacitor RG-213 has a capacitance of 29 pfd/ft Cut more coax than you need for the capacitor Leave 4 inches of center conductor without braid Remove 1” less braid than calculated at 29 pfd/ft Measure capacitance with MFJ 259 or MFJ 269 Trim additional braid and remeasure capacitance Repeat until you arrive at desired value Carefully solder 2” wire at end of braid and solder lug at other end Trim ½ inch of insulation from center conductor and tin with solder. This capacitor measures 15 pfd It is weatherproofed & inserted in Gamma tube, with the center soldered to the SO-239 connector and the terminal lug screwed to the Gamma Tube.

Another method of Tuning Antenna at 25’ in air Antenna is “Clone” Hygain VB64DX with a cost of less than $30.00 Using a Gamma Match from a Cushcraft A5S design.

Tuning Antenna with MFJ-269 Analyzer Frequency of interest 1.3:1 VSWR

Tuning Antenna with MFJ-269 Analyzer 2-1 VSWR High Frequency 51 Tuning Antenna with MFJ-269 Analyzer 2-1 VSWR High Frequency 51.438 MHz

Tuning Antenna with MFJ-269 Analyzer Perfect Match @ 48.432 MHz

Tuning Antenna with MFJ-269 Analyzer 2-1 VSWR Low Frequency 46.076 MHz

The Finished Product ! A “Clone” of the Hygain VB-64DX Commercial Cost = $159.95 My Cost = Less that $ 24.00 Boom came from a broken TH3jr, cost was U-Bolts at ACE hardware. Boom Length = 14 Feet, cut to 12’, Weight = 20 Pounds

Another Finished Product ! A “Clone” of the Hygain VB-66DX Commercial Cost = $265.95 My Cost = Less that $ 30.00 Boom came from a broken 204BA, cost was U-Bolts at ACE hardware. Boom Length = 24 Feet, Weight = 40 Pounds

Feeding the Antenna In order to achieve the desired results, the currents and voltage on the driven element must be balanced, where coaxial cable is unbalanced. Unwanted current on the braid of the coax Use a Balun, a Gamma Match, Beta Match, or a Hairpin Match

Balun A Balun can be purchased through many sources, or you can make a Balun out of Coaxial Cable. Make sure they work at 6 Meters.

Choke Balun Use an aerosol can as a form. Tape 2 nylon tie wraps on opposite sides of the can. Start wrapping the coax tightly around the can. 5 turns is a sufficient Choke Balun for 6 Meters. Secure the turns with the tie wrap, and using a utility razor, trim the end of the coax 9 inches from the choke balun, soldering the center to a terminal lug and the braid to another terminal lug. Coat the brade and center conductor with weather sealant and then wrap with outdoor tape.

Gamma Match 15 5/8” 1 7/8” The Coax Line can be an SO-239 mounted on a small plate at the center of the element. Initially, use an air variable (10-50 pfd) to find the best match. Then measure the capacitance, and replace with a piece of coaxial cable, knowing that RG-8 (Belden 8237) has a capacitance of 29 pfd per foot.

Hairpin Match The Hairpin is balanced and easy to tune. It has the correct electrical and mechanical design to allow it to be easily installed and tuned in 10 minutes and has enough capacity for almost any Yagi design.

Beta Match Similar to the Hairpin Match, with an adjustable shorting length, the Beta Match is fed with a 1 to 1 Balun.

Any Questions?