Re: Portable Aircraft HF Radio Build (Going to Be Long) Multiple Posts....

NW_Pilot wrote:
"NW_Pilot" <service(Spam)@aircraft"nospam"-me-ok-"spamer"delivery.net> wrote in message news:v_idnYqCWoAcMwTanZ2dnUVZ_tSknZ2d@xxxxxxxxxxxxxx
Hello, Usenet, Jay, Marry, Montblack, And Friends!!!

Since Comcast is so lame and Lost the HF thread will start my own.

HF-Box build project, Goal is to simplify next flight T182T to Qatar next week!!! and return airline flight home with equipment not broken.

Most all you know what I do for a living fun, fun, fun, :-) yep mostly Single Engine Piston Aircraft Over Oceans it some times requires an HF Radio!

Well I got tired of always fumbling with HF wiring Special Flight Permit Allows!! A Power Drop For HF When Tanked!! So I decided to package it all in to one small portable airline carry on size case case. I used a Pelican case just incase I may be harassed and asked to check it as I have in the past (Thanks!! Delta, Virgin, and TSA A-holes)

This Case Will Not Be Water Tight It Requires Drilling Holes!!!! Pelican Unconditional Warranty Still Applies Leaving Holes To Min. MADE IN USA WITH GREAT WARRANTY!!!

Supply List,

Pelican 1450 Case About $75.00 Shipped (No Foam)
HF Radio ICOM 706MKIIG 100 Watt $949.00 On Sale Ham Radio Outlet (Remote Mount Kit Required It's Usually Free + a $50 to $100 Rebate) Look Here http://www.icomamerica.com/amateur/hf/index.html#706
Automatic Antenna Tuner SGC 237 100 Watt (or 239) $359.00
Astron 24 to 12V Converter 20 Amp 24 Peak About $150.00
2 Nice Size Pieces Of Aluminum ($ Varies Mine Was Donated By Horizon Air Trash Can! Yea, I Dumpster Diving Again!!)
A Bunch Of Mics. Items Don't feel like Listing them All Use Your Brain!!! (Jacks PL235 1000UF 25V Cap And 10K Resister, 1 or 2 Computer Fans Etc.) MCM, Norvac, Etc. ($$ Varies)
Tools, Tin Snips Left, Right, Straight, Soldering Iron, Solder, Drill And Assorted Bits, Rivet's And Rivnuts...Lots of Heat Shrink, Epoxy, Your Brain, and Harbor Freight If you have a local one!!! (My Case Friends Snap-On Truck & My Own Good Tool Collection)

You will need Soldering Skills, An Adult Beverage I Like Whiskey, Kitchen (Aka, Workshop) And AN Understanding Wife!!! For making a Big Mess!!!

This Pelican Case will give you enough Space to Pack The Radio, Long Wire Antenna, Tools, And Universal Mounting Hardware Cessna, Piper, Grumman, Etc... Single And Multi All Connections Antenna's. Power, Ground And Control head will be External Mount Quick Connect.

Photos Will Be Out Of Numerical Order,
The Case, Pelican 1450 Perfect Size About $70.00 No Foam
http://www.internationalferryflights.com/HF_BOX/S4010546.JPG
http://www.internationalferryflights.com/HF_BOX/S4010544.JPG

Take You *** Of Aluminum Cut it To Fit The Bottom Of the Pelican Case. Don't Cut your Fingers....I did not want to use my CNC mill for this to much work to clean the Garage to get to the dam thing. Ok, Mount the Radio Mount To This!!! I Used 1/8" Pop Rivets...
http://www.internationalferryflights.com/HF_BOX/S4010541.JPG
http://www.internationalferryflights.com/HF_BOX/S4010542.JPG

Verify Fit In Case, Looks Ok!
http://www.internationalferryflights.com/HF_BOX/S4010545.JPG

Remove From Case and Mount Radio
http://www.internationalferryflights.com/HF_BOX/S4010547.JPG
http://www.internationalferryflights.com/HF_BOX/S4010548.JPG

Verify Fit In Case, You want About 1/2 Inch for Cable Clearance On Front Remote Mount Cable.
http://www.internationalferryflights.com/HF_BOX/S4010549.JPG
http://www.internationalferryflights.com/HF_BOX/S4010550.JPG

Time To Mount The Antenna Tuner, Ok I used scotch bright pads with a right angel die grinder to remove the paint off the bottom of the SGC-237 (No Photo) because if you have not guessed it by now we are using the aluminum *** as a ground for this project. A good ground with a wire antenna is key for this set up.

http://www.internationalferryflights.com/HF_BOX/S4010552.JPG

Verify Fit In Case, Make Another Adult Beverage!!!
http://www.internationalferryflights.com/HF_BOX/S4010553.JPG
http://www.internationalferryflights.com/HF_BOX/S4010554.JPG

Find A Spot For Cooling Fan Placement, (I Do Have A Guard For The Fan)
http://www.internationalferryflights.com/HF_BOX/S4010555.JPG

Remove Lid Re Clock 180 Degrees Add Auto Tune Cap & Resister To the Inside Of Tuner At The Terminal Connector.
http://www.internationalferryflights.com/HF_BOX/S4010559.JPG

More Inside the SGC237
http://www.internationalferryflights.com/HF_BOX/S4010560.JPG

Preview Of Mounting Astron Voltage Converter to lid Of SGC-237 Antenna Tuner,
http://www.internationalferryflights.com/HF_BOX/S4010557.JPG
http://www.internationalferryflights.com/HF_BOX/S4010558.JPG



Day-2

Drilling the vent holes for fan.
http://internationalferryflights.com/HF_BOX/Day-2/S4010563.JPG
http://internationalferryflights.com/HF_BOX/Day-2/S4010564.JPG
http://internationalferryflights.com/HF_BOX/Day-2/S4010565.JPG
http://internationalferryflights.com/HF_BOX/Day-2/S4010566.JPG
http://internationalferryflights.com/HF_BOX/Day-2/S4010569.JPG

SGC-237 to 706 Hookup
Manufactures Instructions I did it but put it inside the tuner.
http://www.sgcworld.com/Publications/Downloads/ic706connecting.pdf
Mine Inside The Tuner,
http://internationalferryflights.com/HF_BOX/Day-2/S4010575.JPG
The Molex Connector,
http://internationalferryflights.com/HF_BOX/Day-2/S4010578.JPG
Wiring Hooked Up,
http://internationalferryflights.com/HF_BOX/Day-2/S4010584.JPG
http://internationalferryflights.com/HF_BOX/Day-2/S4010587.JPG
http://internationalferryflights.com/HF_BOX/Day-2/S4010588.JPG

Mounting the Astron to the 237, Use Nylon Screws as they is high Voltage,
http://internationalferryflights.com/HF_BOX/Day-2/S4010581.JPG
http://internationalferryflights.com/HF_BOX/Day-2/S4010582.JPG
http://internationalferryflights.com/HF_BOX/Day-2/S4010583.JPG

Astron Mounted to 237,
http://internationalferryflights.com/HF_BOX/Day-2/S4010590.JPG
http://internationalferryflights.com/HF_BOX/Day-2/S4010591.JPG

706MKIIG Power Line Routing, to Astron
http://internationalferryflights.com/HF_BOX/Day-2/S4010594.JPG
http://internationalferryflights.com/HF_BOX/Day-2/S4010595.JPG
http://internationalferryflights.com/HF_BOX/Day-2/S4010596.JPG

Antenna, Connector, 3 Pin Power Connector, (Will Have Switch to Select 14V or 28V System) All protected between hard plastic. plenty of room to connect the cables.

http://internationalferryflights.com/HF_BOX/Day-2/S4010600.JPG
Inside, decided to go with a thermaltake fan nice and quiet.
http://internationalferryflights.com/HF_BOX/Day-2/S4010602.JPG
Inside With Radio,
http://internationalferryflights.com/HF_BOX/Day-2/S4010603.JPG
Added And Airframe Ground,
http://internationalferryflights.com/HF_BOX/Day-2/S4010604.JPG

1/2' Foam,
http://internationalferryflights.com/HF_BOX/Day-2/S4010605.JPG

Radio Fitted with Foam Under Aluminum,
http://internationalferryflights.com/HF_BOX/Day-2/S4010607.JPG

Still have some wiring to do for main power and 14 Volt and 24 Volt, Need to wire an 8pin connector under the power for remote mount control head... Depending on if the junk store is open or not Monday I should have it done and ready to test. May have to D sub the Control Head. really want to use a 8pin round connector similar to the power.


BBL...



Called norvac and ordered the rest of the parts today... so it's drive 40 miles round trip traffic and snow or pay $8.00 for shipping should be here tomorrow.

The $50.00 remote separation cable is an 8 conductor cable so I ordered P700 And T700 microphone connectors,

http://internationalferryflights.com/HF_BOX/2399.jpg
&
http://internationalferryflights.com/HF_BOX/micplugz.jpg

Possible mount under the handle or below the power cable.


Tasks today is the External fan nod to the radio to help with cooling,

Instructions here, http://www.dxzone.com/cgi-bin/dir/jump2.cgi?ID=10087

Will finish 98% of the wiring for 28V/14v system,

Wire Tune Locked LED to case

Make a fee ground straps.

Clean up kitchen table, prepare for finial assembly & testing.

Wire roof with coper wire and coax for testing, And why dose it have to snow/rain every time I get on the roof?














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