Portable Equipment Frames

Photograph 1: 

AD5TD’s “Ham in a Can”

 

This is Bill’s, AD5TD’s, complete portable station built into a chuck box.  It includes two 37 Ah gel cells and a charger and weighs in at about 75 pounds.  Its great in the field but a little bulky for my operating desk in my shack.
 

Photograph 2: 

Front View of Frames

 

Here the frames with the attached equipment have been set up in a portable environment.  The HF frame is to the left, and the VHF/UHF radio and power supply frame with speaker is to the right.  The front tilt legs are being used to raise the front of the frames. 

Photograph 3: 

Frame Components.

 

Three wood pieces for one of the frames are shown here.  Note the two dado joints on the side pieces.  This is an extremely simple design.  The wood is an inexpensive lightweight imported birch.

Photograph 4: 

HF Frame

 

Two wood pieces are being trial fitted together to check for the correct width of the dado cut.  If the fit is too tight it will be difficult to assemble the pieces after glue is applied to the joint. 

Photograph 5: 

HF Frame

 

One side of the HF frame is being glued and nailed.  Use a wet paper towel to clean up any glue drips before they dry.

Photograph 6: 

HF Frame

 

The nails are being counter-sunk by tapping the nail heads with a larger nail.
 

Photograph 7: 

Wood Filler

 

Two colors of wood filler are being mixed to match the color of the wood frames.

Photograph 8: 

HF Frame

 

The nail holes are being filled in.

Photograph 9: 

VHF/UHF Frame

 

The first coat of water based varnish (polyurethane) is being applied to one of the frames.  Since this dries quickly four coats can be applied in one day.

Photograph 10: 

Side of Frame

 

The holes for the bolts holding the tilt legs were counter-sunk to keep the heads of the bolts flush with the sides of the frames.  Its all 3/8 inch stainless steel hardware.

Photograph 11: 

Side of Frame

 

This bolt is being permanently attached to the frame with epoxy.
 

Photograph 12: 

Tilt Legs

 These are the tilt legs after they were cut out, and before they were sanded.  They were cut from the same type of wood as the frames.

Photograph 13: 

Inside of HF Frame.

 

The tilt legs are secured to the frames by installing a wide fender washer and a nylon insert locking nut over the bolt.  The nuts are snugged up so it takes some effort to rotate the legs.  This gives the assembly more stability.

Photograph 14: 

Ammo Box

 

Installing double sided tape to the inside of the box.  The carpet tape that was used was not very sticky but just enough to keep the foam in place.
 

Photograph 15: 

Ammo Box

 

Installing the foam to the inside of the box.  The tapered pieces of foam were cut to shape by trial and error.

 

Photograph 16: 

Top of VHF/UHF Frame

 

Note the arrangement of the power wiring harness.  The wire connections were first wrapped with light wire and then soldered with a large iron.  After using a generous amount of electrical tape the harnesses were tacked to the sides of the frame with coax clamps.  I later used nylon cable clamps.  There are what I call a "poor man's rig runner".  Note all power connections are Anderson Powerpoles, an absolute must.

Photograph 17: 

HF Frame and Box

 

Here my XYL, Jane, is placing the HF frame into its padded ammo box.  Note that the tilt legs have been folded back to save space.

Photograph 18: 

Top of Ammo Box

 

Note the gap between the top of the foam and the frame allowing for additional storage, such as the few loose cables not connected to the frames, microphones, etc.

Photograph 19: 

Front View of HF Frame

 

The front legs are shown in the down position.  The front of the frame is raised up about 2½ inches higher than the rear, giving good access to the controls and making the displays easy to read.

Photograph 20: 

Top View of HF Frame

 

This shows the attachment of the angles to the power supply and the wood frame.  Heavier pieces of equipment require more angle length and more attachment screws.
 

Photograph 21: 

Front View of HF Frame

 

Note the clearance provided above the transceiver for ventilation, and the way the angle is attached to the radio and the frame.

 

Photograph 22: 

Rear View of HF Frame

 

Note the interconnecting cables to the HF modules and the clearance provided for them at the rear of the wood frame.  There are an infinite number of layouts possible with this type of design and the one you chose will depend on the size of your equipment, the size of the containment boxes and how much you can carry.

Photograph 23: 

Wiring Harness

 

Note the use of cable ties to attach the wiring to the frame.
 

Photograph 24: 

Remote Head Cable

 

Note that extra lengths of cable can be bundled together and attached to the frame with cable ties.

Photograph 25: 

Remote Head Cable

 

Note the use of a cable tie as a strain relief and attachment method.
 

Photograph 26: 

Notch for Cables

 

The notch in the edge of the wood frame and a cable tie allow the cables to be routed to the opposite side.

Photograph 27: 

VHF/UHF Installation

 

Note the use of cable ties to restrain all cables.

 

Photograph 28: 

VHF/UHF Installation

 

This module also contains the power supply, speaker and modem.  Note how the modem is attached.  Also note the recessed opening in the wood frame to allow access and viewing of the remote head controls.
   
Steven Pituch, W2MY, wins April QST Cover Plaque Award (May 2, 2007) -- The winner of the QST Cover Plaque Award for April is Steven Pituch, W2MY, for his article "A Portable Equipment Support Frame." Congratulations, Steve! The winner of the QST Cover Plaque award -- given to the author or authors of the best article in each issue -- is determined by a vote of ARRL members on the QST Cover Plaque Poll Web page.

 

 
UPDATE: 2/18/2008 - This is a new frame to carry a TS-480SAT, an MFJ-949E tuner and a PK232 TNC.  

 

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