HF Yagi Refurbishment

HF Yagi Refurbishment
Status	In Progress
Project Lead	User:TylerWard

HF Yagi Refurbishment

The clubs HF Yagi (a Cushcraft A-3S antenna) is in need of some refurbishment to put it back into a usable state. Some parts of the antenna have either corroded away or have been lost and need replacing, while others can be restored to working order.

Antenna Details

The HF Yagi is believed to be a Cushcraft A-3S.

This is a 20m, 15m ,10m yagi.

It was acquired as it was being thrown out by a Scout Club near Basingstoke, prior to the departure of their only licensed staff member.

Cushcraft Product Page

A-3S Assembly Manual (pdf)

Inventory page

Remaining tasks

• test
• Punch in trap ends to secure spacers
• add remaining trap endcaps
• Purchase required assembly tools
• Create bracket for balun box
• Stamp IDs into Traps

Parts List

From Manual

Code	Desc	required	have	location	notes/link to buy	QC
BA	Aluminium tubing 1-5/8" x 12" (4.1 x 30.5 cm) drilled and slotted both ends	1	0		replace with solid boom
BB	Aluminium tubing 1-1/2" x 84" (3.8 x 213.4 cm) drilled one end	2	0		replace with solid boom
EA	Aluminium tubing 1-1/8" x 72" (2.9 x 182.9 cm) drilled for U-bolt, slotted both ends.	2	2	long bag	slightly bent marked as blue 3 and black 3	QC7
EB	Aluminium tubing 1-1/8" x 36" (2.9 x 91.4 cm) drilled one end, slotted both ends	2	2	long bag	marked as red 3	QC7
EC	Aluminium tubing 1" x 67" (2.5 x 170.2 cm) slotted one end	2	2	long bag	marked as black 2	QC7
ED	Aluminium tubing 1" x 65" (2.5 x 165.1 cm) slotted one end	2	2	long bag	marked as red 2	QC7
EE	Aluminium tubing 1" x 46-1/2" (2.5 x 188.1 cm) slotted one end	2	2	long bag	marked as Blue 2	QC7
EF	Aluminium tubing 1" x 5-1/4" (2.5 x 13.3 cm) slotted both ends	6	6	short bag		QC7
EG	Aluminium tubing 1/2" x 35-7/8" ( 1.3 x 91.1 cm)	6	5	short bag	end elements (marked as red 1, blue 1 and black 1) (one damaged needs replacing)	QC7*
TA	10 metre trap	6	6	short bag	these are the ones that are big on both ends (some end caps missing)	QC7**
TB	15 metre director trap	2	2	short bag	mixed with TC's needs sorting (some end caps missing)
TC	15 meter driv. & refl. trap	4	4	short bag	mixed with TB's needs sorting (some end caps missing)
11	010011 #8-32 hex nut	6 4	0
33	190033 Backing plate	2	0
41	011941 #8 split lock washer	6 4	0
46	050046 1-1/2" (3.8 cm) black plastic cap	2	0		do we want to cap the new boom
53	050053 1/2" (1.3 cm) black plastic cap	6	2			QC Failed
58	173658 3-1/2" (8.9 cm) V-block	2			Used on boom to mast assembly (alternate assembly will be used)
63	170063 2" (5.1 cm) V-block	2			Used on boom to mast assembly (alternate assembly will be used)
84	010084 1/4" (.6 cm) lock washer	6	0
85	010085 1/4" (.6 cm) hex nut	6	0
96	122096 10" (25.4 cm) fibreglass insulator	1	1	long bag	marked as red 3	QC7
118	010118 5/16" (.8 cm) hex nut	8			Used on boom to mast assembly (alternate assembly will be used)
119	010119 5/16" (.8 cm) lock washer	8			Used on boom to mast assembly (alternate assembly will be used)
120	010120 #8-32 x 2" (5.1 cm) machine screw	2			used on boom not required
123	010123 #8-32 x 1-1/2" (3.8 cm) machine screw	2	0
143	190143 1-1/8" (2.9 cm) aluminium bracket	3	0
326	290326 Danger label	1	0
402	010402 1-1/2" x 3-3/4" (3.8 x 9.6 cm) U-bolt	3	0
403	010403 1-5/8" (4.1 cm) U-bolt	2			Used on boom to mast assembly (alternate assembly will be used)
404	010404 2-1/8" x 3" (5.4 x 7.6 cm)	2			Used on boom to mast assembly (alternate assembly will be used)
409	030409 11/16" (1.7 cm) worm clamp	6	0		all jubilee clips should be replaced
410	030410 1" (2.5 cm) worm clamp	18	0		all jubilee clips should be replaced
411	030411 1-1/8" (2.9 cm) worm clamp	8	0		all jubilee clips should be replaced
413	030413 1-5/8" (4.1 cm) worm clamp	2	0		used on boom not required
453	100453 Terminal	2	0		check balun fittings before ordering
919	190919 6" x 6" (15.2 x 15.2cm) mounting plate	1			Used on boom to mast assembly (alternate assembly will be used)

Additional/Alternate Parts

• Balaun
• 1.5in 14ft aluminium pole as boom
  • We have just (26th September 2016) acquired 3 approximately 15.5ft (4.72m) long 1.5in (40mm) aluminium poles which have a 1/8in (3-4mm) thickness. daveruss is currently storing these in his garage.
• varnish/paint

Shopping list

Cushcraft

Cushcraft Code	QTY
EG	1
11	4
33	2
41	4
53	6
84	6
85	6
123	2
143	3
326	1
402	3

Other

• Jubilee clips
• Ring terminals

Reference Photos

Old Boom

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Traps

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