Use the following instructions to construct a jig and mast kit to utilize a flag pole to put up an antenna with a base elevation of 5’ taller than the flag pole. On several occasions, I have use a 40’ light pole to gain very good long distance communication. This kit was designed for a flag pole but will work with any round light pole as well with a slight modification. This kit is simple and inexpensive (~$30) to build and will fit in the trunk of any car. The kit does not include the antenna nor the coax feed line. The kit can be installed on a flag pole by one person, but it is MUCH easier with two.
PURCHASED PARTSQty Description
1 Chain Link Fence Rail Top Pipe 10’ long. 8 1/2” PVC long radius 90 deg electrical conduit fittings.
1 PVC Pipe Cleaner / Glue set.
1 75’ of 1/16” nylon cord on wind up loop.
1 1/4” Spring Link.
20” Fencing wire.
2 1/4” x 2 1/2” Bolt.
2 1/4” Nut.
2 1/4” Split ring lock washer.
2 5/16” Washer.
1 3/4” Outside diameter Fender or Dock Washer.
1 1/4” x 3” Carriage bolt.
2 1/4" Nut.
1 3/8” Nut.
TOOLS- Hack saw
- 3/32” drill bit
- 1/4” drill bit
- Drill
- Small Steel File
- If possible: Drill Press, Steel Pipe cutter, Bench Grinder
INSTRUCTIONS: FLAG POLE GUIDES
1. The 1/2” PVC long radius 90 deg electrical conduit fittings will make a larger diameter Pole Guide than you need in most cases, so I recommend cutting them off to reduce the inside diameter to about 25”. Beginning at the bell end of the 90 deg fitting, measure the outside circumference and cut it to 9.25”.
2. Drill a 1/4” hole through the side of one 90 deg fitting as shown in Figure 3.
3. Loosely fit (4) 1/2" PVC 90 deg fittings together to form a circle. Make sure these 90’s are square by pressing this assembly onto a flat surface.
4. Remove (2) of the fittings and glue them together. Loosely but quickly fit them back onto the other two fittings to make sure the glue joint is square. You only have a few seconds to get it square. Hold the assembly together until the glue sets because the fittings have a tendency to slide back out of the bell ends. This holding of parts together applies for all future glue joints.
5. Repeat step 3 for the other (2) fittings such that you end up with two half circles glued together.
6. Repeat steps 1-5 to form the second Pole Guide.
7. Cut out the fitting taper from the bell ends of the 90 deg fitting that were not glued together. The inside diameter of the fittings must be at least 0.85”. This is just slightly larger than the outside diameter of the pipe. The pipe should slip easily all the way into the base of the 90 deg fittings. Check each fitting individually. I had to create a special tool to cut the taper out of the 90’s. This is a critical step to make sure the Pole Guide is easy to assemble and disassemble. If the taper is not removed, it is nearly impossible to disassemble once pushed together. See instructions below for creating the Taper Cutter tool.
8. Fit the two half circles of the Pole Guide tightly together. Use a drill press to drill a 3/32” hole through the bell end of the 90’s that have not been glued (2). The hole should be 1/2 way between the ends of the bell. See Figure 3. This can be done with a drill but it is harder to get it straight. After drilling these holes, ensure that you do not mix up which half circle was matched with the other. You may want to mark the half circles which fit together.
9. Repeat step 8 for the other Pole Guide.
10. Use some fencing wire to make removable pins for these holes. See Figure 3.
11. Tie one end of the 1/16” nylon cord to the Spring Link.
INSTRUCTIONS: FLAG POLE MAST
1. Cut the (1) Fence Rail Top Pipes in half (63” lengths).
2. Tightly place the factory tapered end of the Fence Rail Top Pipe into the piece of pipe without any taper. The factory tapered pipe will be the bottom of the mast.
3. 1.5” from the end of the pipe, drill a 1/4” hole through both sided of the two pieces of pipe. Flare these holes a bit to make it easier to fit the bolt.
4. Fit the 1/4” bolt through this hole to keep it straight and help align the next hole to be drilled.
5. 1.5” from the bottom end of the factory tapered pipe, drill a 1/4” hole through both sided of the pipe. Make sure this hole is drilled in the same orientation as the first hole.
INSTRUCTIONS: TAPER CUTTER TOOL – (~45 min)
1. Use a 3/4” steel washer to create a Taper Cutter tool to remove the taper from the pipe fittings.
2. Use a hack saw to cut 4 slots into the washer about 1/8” deep.
3. Use a bench grinder or file to grind out the gray area of the washer.
4. Sharpen the front cutting edge of the tool with a file.5. Once the cutter is roughly cut out, bolt it onto a shaft like shown in the picture.
6. Use a file while the cutter is rotating in a drill press or drill to adjust the diameter of the cutter so that it removes just enough of the fitting taper.
NSTRUCTIONS: PUTTING UP THE ANTENNA on a FLAG POLE - (~15min)
1. Attach both Flag Pole Guides to the mast using the 1/4” bolts and washers. The lock washer must be placed between the Fence Rail Pipe and the nut. Tighten the bolts so they will not come loose.
3. Attach the antenna to the top of the mast.
4. Attach the coax to the antenna. Tie the coax to the pipe with a tie rap.
5. Attach the Flag Pole Guide & Mast assembly along with antenna around the flag pole using the wire pins in the Flag Pole Guides.
6. Lay out the coax so that it will easily play out as the antenna is raised up the pole.
7. Use the Spring Link to attach the 1/16” cord to the nylon loop from Step 2.
8. Attach the flag pole rope to the nylon loop from Step 2.
9. Use the flag pole rope to pull the assembly up the flag pole. The 1/16” cord can be used to help guide the assembly and antenna past the end of the flag pole.
10. Use the nylon cord and “Maypole” the cord around the mast, coax, and flag pole. This will secure everything and make everything quite stable. The nylon cord has some stretch to it, so pull it tight as you wrap the pole.
11. Tie off the end of the cord once it is wrapped all the way around down to the base of the flag pole. This will keep the cord tight.
12. Your antenna is now ready for use.
INSTRUCTIONS: PUTTING UP THE ANTENNA on a ROUND LIGHT POLE - (~15min)
1. To use a round light pole, throw the Spring Clip and 1/16” nylon cord over a horizontal brace at the top of the pole.
2. Use the same instructions as for the Flag Pole except that the 1/16” cord will be used to raise the assembly to the top of the light pole.
INSTRUCTIONS: TAKING DOWN THE ANTENNA - (~15min)
Taking down the antenna is mostly the reverse of putting it up.
