Lightning Strikes! Rebuilding my SteppIR antenna and tower installation

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Lightning Strikes! Rebuilding my SteppIR antenna and tower installation

Table of Contents:

  1. Introduction
  2. The Damage caused by lightning 2.1. Comparison between old and new Ehus 2.2. Shattered sprockets in the old Ehus
  3. Rebuilding the damaged stepper 3.1. Finding good motors from an old stepper
  4. The 36-foot boom and 40-meter return bracket
  5. Repairing the fiberglass and repainting
  6. Tips and new sprockets for the elements
  7. Connection box replacement
  8. Choosing the right paint
  9. Removing the old motor and coax connector 9.1. Removing the top plate 9.2. Driving out the pin
  10. Dismantling the newer housing 10.1. Removing the egg pieces 10.2. Backing out the tape 10.3. Putting tension on the spools 10.4. Mounting the board and removing the tape
  11. Mounting the rebuilt stepper onto the tower 11.1. Attaching the rotor and main pipe 11.2. Installing the boom and control wires
  12. Additional antennas and raising the tower 12.1. The 30-meter rotatable dipole 12.2. The five-element six-meter beam
  13. Conclusion

Rebuilding a Damaged Four-Element Stepper Antenna

Introduction

In this article, we will follow Steve W9SN as he demonstrates the process of rebuilding a four-element stepper antenna that was damaged by lightning. He will guide us through the steps involved in repairing the damaged components and restoring the functionality of the antenna. By the end of this article, You will have a clear understanding of the rebuilding process and the necessary steps to get your own antenna back up and running.

The Damage caused by Lightning

The first step in the rebuilding process is to assess the damage caused by the lightning strike. Steve compares the old and new Ehus, noting the differences in their construction. He points out that the new Ehus have black shafts and refers to them as sprockets. In contrast, the older Ehus have a greenish-gray color and their sprockets were made of a light gray plastic material.

Shattered Sprockets in the Old Ehus

Upon closer inspection, Steve shows us an Ehu with a broken sprocket caused by the lightning strike. He explains that the older sprockets had a tendency to shatter, making them unable to drive the tapes in and out of the Ehu. He also points out that the older Ehus had a Roll Pin instead of a bolt like the newer ones. This further contributed to the vulnerability and breakage of the sprockets.

Rebuilding the Damaged Stepper

To rebuild the damaged stepper, Steve decides to find good motors from an old stepper. He shows us the process of removing the old motor and coax connector, as well as dismantling the newer housing to access the motor. By replacing the damaged components with functional ones, Steve ensures the stepper's proper operation.

The 36-Foot Boom and 40-Meter Return Bracket

Steve showcases the 36-foot boom of the four-element stepper antenna. He explains its purpose and mentions that it has a 40-meter return bracket, although he decides not to utilize it for his specific setup.

Repairing the Fiberglass and Repainting

Due to exposure to the sun over time, the fiberglass components of the stepper antenna have faded and become damaged. Steve demonstrates how to repaint them using Rust-Oleum Topsides, a marine paint designed for outdoor use. He opts for a navy Blue color instead of the original green, providing both aesthetic appeal and protection against the elements.

Tips and New Sprockets for the Elements

Steve replaces the old tips of the antenna's elements with new ones that have a stainless screen and foam inside. Additionally, he shows us a spare sprocket that will be utilized during the rebuilding process. These new components ensure the longevity and functionality of the antenna.

Connection Box Replacement

The connection box located at the center of the tower suffered heavy damage from the lightning strike. Steve replaces the old, disintegrated box with a new one. He also applies dielectric grease to the ends of the copper wire connected to the new cable, ensuring optimal conductivity and protection.

Choosing the Right Paint

In the process of repainting the fiberglass components, Steve decided to use Rust-Oleum Topsides, a marine paint specifically made for outdoor use. He explains that this paint does not contain carbon and is an excellent fit for the stepper antenna.

Removing the Old Motor and Coax Connector

Steve demonstrates how to remove the old motor and coax connector from the stepper antenna. He disassembles the top plate and drives out the pin that holds the motor in place. This step allows for the replacement of the damaged components with functional ones.

Dismantling the Newer Housing

To access and replace the motor in the newer housing, Steve demonstrates the dismantling process. He removes the egg pieces, backs out the tape, puts tension on the spools, and removes the top plate. This enables the replacement of the motor and the smooth operation of the antenna.

Mounting the Rebuilt Stepper onto the Tower

Steve shows us how to mount the rebuilt stepper antenna onto the tower. He attaches the rotor, main pipe, and boom truss to secure the antenna properly. The control wires are neatly run underneath the boom for protection against sun damage. This ensures the stability and functionality of the antenna.

Additional Antennas and Raising the Tower

Steve adds a 30-meter rotatable dipole and a five-element six-meter Beam to the tower. These additional antennas provide expanded coverage and capabilities. He demonstrates the process of raising the tower, which is motor-driven and features an ACME screw. This allows for effortless lifting and lowering of the tower to carry out maintenance and adjustments.

Conclusion

In conclusion, Steve W9SN's rebuilding process of a damaged four-element stepper antenna highlights the steps necessary to restore its functionality after a lightning strike. From the assessment of the damage to the replacement of components and the mounting on the tower, he meticulously guides us through each stage. By following these instructions, you too can rebuild and repair your own damaged antenna, ensuring optimal performance and longevity.

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