M2 Antenna Systems 40M3FS Assembly Manual page 2

40M3FS ASSEMBLY MANUAL
Tool required: 7/16", 1/2 and 9/16" end wrenches or sockets, #2 Phillip screwdriver and
11/32 nut driver or equivalent.
THE FOLLOWING ARE SIMPLIFIED INSTRUCTIONS. YOU WILL NEED THIS WRITTEN
SECTION TO HELP SET THE ORDER OF ASSEMBLY AND TO COVER THE MOST IM-
PORTANT POINTS.
We have provided Penetrox (zinc paste / anti seize compound) that you should put on the
tubes at every joint prior to assembly. It also serves as an antiseize lubricant for all the
hardware. Also put just a tiny dab on every thread just before assembly and you should
have no trouble with sections binding or bolts seizing during assembly.
1. IF SPACE IS A PROBLEM, we suggest you build just the tips of the elements first. Start
with the 1-1/2" sections. If the 1-3/8 sleeves are separate, insert them into the butt of each 1-
1/2 inch section, align the holes and insert an eyebolt and nut loosely just to keep things
aligned. Now add the 1-1/4" section and its sleeve. Bolt and screw sizes are noted on the
element assembly sheet. Continue adding sections until you get the 1/2 inch sections. The
REFLECTOR element requires slightly more length so 3/8" diameter tips are required.
2. It may be convenient at this time to determine just what part of the band you want to opti-
mize. NOTE the DIMENSION SHEET has 4 choices of tip dimensions. These match up
with 3 choices of spacing which will come later in the assembly. Adjust EXPOSED TIP
LENGTH (SEE COMPRESSION CLAMP DETAIL SHEET) for your band segment choice.
This will allow for band change later, should you find it desirable.
3. Build the center sections of the REFLECTOR AND DIRECTOR next. Mark the center of
the 2-1/2" x 158 inch sections and attach the elements to the 8 x 1/4" plate using 2-1/2 sad-
dles and 3/8-16 x 4" bolts and locknuts. Align the element holes perpendicular to the plate
and tighten. Add the 3" saddle clamps that connect the plates to the antenna boom. Leave
the nuts finger tight as this will allow the element to just slide on over the end of the boom.
You can also install the welded vertical riser element supports at this time using 1/4-20 x 1"
bolts and locknuts, put the bolts in from the bottom of the assembly and tighten securely.
4. Now assemble the DRIVEN ELEMENT center section. Mount the 2" X 36" FIBERGLASS
center insulator on the remaining 8 x 8 x 1/4" element mounting plate using two sets of 2"
saddles. Use 3/8-16 bolts and locknuts. Center the insulator, rotate the insulator so the ele-
ment mounting holes are perpendicular to the plate and tighten the hardware. Install the
welded vertical riser element support at this time using 1/4-20 x 1" bolts and locknuts. Put
the bolts in from the bottom of the assembly and tighten securely. Slide each MARKED ele-
ment half over the insulator, align the holes and add the bolts as shown on the element as-
sembly sheet.
5. Next add the 5/16" TURNBUCKLES to the top plates of the risers. Add the black Philis-
tran HTPG 1200 x 19 ft. cords at this time. Use a 3/6" thimble and two wire clips (small u-
bolts to secure cable).