Portable Aircraft HF Radio Build (Going to Be Long) Multiple Posts....

I already have built an adapter to use a standard aviation headset that plugs in
to the control head.

Aha! Any way I could get my hands on such an adapter? Or some help
on how to put it together?
Gerd

NW_Pilot wrote:
NW_Pilot wrote:
"NW_Pilot"
wrote in message . ..
Hello, Usenet, Jay, Marry, Montblack, And Friends!!!

Since Comcast is so lame and Lost the HF thread will start my own.

HF-Box build project, Goal is to simplify next flight T182T to Qatar
next week!!! and return airline flight home with equipment not broken.

Most all you know what I do for a living fun, fun, fun, :-) yep
mostly Single Engine Piston Aircraft Over Oceans it some times
requires an HF Radio!

Well I got tired of always fumbling with HF wiring Special Flight
Permit Allows!! A Power Drop For HF When Tanked!! So I decided to
package it all in to one small portable airline carry on size case
case. I used a Pelican case just incase I may be harassed and asked
to check it as I have in the past (Thanks!! Delta, Virgin, and TSA
A-holes)

This Case Will Not Be Water Tight It Requires Drilling Holes!!!!
Pelican Unconditional Warranty Still Applies Leaving Holes To Min.
MADE IN USA WITH GREAT WARRANTY!!!

Supply List,

Pelican 1450 Case About $75.00 Shipped (No Foam)
HF Radio ICOM 706MKIIG 100 Watt $949.00 On Sale Ham Radio Outlet
(Remote Mount Kit Required It's Usually Free + a $50 to $100 Rebate)
Look Here http://www.icomamerica.com/amateur/hf/index.html#706
Automatic Antenna Tuner SGC 237 100 Watt (or 239) $359.00
Astron 24 to 12V Converter 20 Amp 24 Peak About $150.00
2 Nice Size Pieces Of Aluminum ($ Varies Mine Was Donated By Horizon
Air Trash Can! Yea, I Dumpster Diving Again!!)
A Bunch Of Mics. Items Don't feel like Listing them All Use Your
Brain!!! (Jacks PL235 1000UF 25V Cap And 10K Resister, 1 or 2
Computer Fans Etc.) MCM, Norvac, Etc. ($$ Varies)
Tools, Tin Snips Left, Right, Straight, Soldering Iron, Solder, Drill
And Assorted Bits, Rivet's And Rivnuts...Lots of Heat Shrink, Epoxy,
Your Brain, and Harbor Freight If you have a local one!!! (My Case
Friends Snap-On Truck & My Own Good Tool Collection)

You will need Soldering Skills, An Adult Beverage I Like Whiskey,
Kitchen (Aka, Workshop) And AN Understanding Wife!!! For making a Big
Mess!!!

This Pelican Case will give you enough Space to Pack The Radio, Long
Wire Antenna, Tools, And Universal Mounting Hardware Cessna, Piper,
Grumman, Etc... Single And Multi All Connections Antenna's. Power,
Ground And Control head will be External Mount Quick Connect.

Photos Will Be Out Of Numerical Order,
The Case, Pelican 1450 Perfect Size About $70.00 No Foam
http://www.internationalferryflights...X/S4010546.JPG
http://www.internationalferryflights...X/S4010544.JPG

Take You Sheet Of Aluminum Cut it To Fit The Bottom Of the Pelican
Case. Don't Cut your Fingers....I did not want to use my CNC mill for
this to much work to clean the Garage to get to the dam thing. Ok,
Mount the Radio Mount To This!!! I Used 1/8" Pop Rivets...
http://www.internationalferryflights...X/S4010541.JPG
http://www.internationalferryflights...X/S4010542.JPG

Verify Fit In Case, Looks Ok!
http://www.internationalferryflights...X/S4010545.JPG

Remove From Case and Mount Radio
http://www.internationalferryflights...X/S4010547.JPG
http://www.internationalferryflights...X/S4010548.JPG

Verify Fit In Case, You want About 1/2 Inch for Cable Clearance On
Front Remote Mount Cable.
http://www.internationalferryflights...X/S4010549.JPG
http://www.internationalferryflights...X/S4010550.JPG

Time To Mount The Antenna Tuner, Ok I used scotch bright pads with a
right angel die grinder to remove the paint off the bottom of the
SGC-237 (No Photo) because if you have not guessed it by now we are
using the aluminum sheet as a ground for this project. A good ground
with a wire antenna is key for this set up.

http://www.internationalferryflights...X/S4010552.JPG

Verify Fit In Case, Make Another Adult Beverage!!!
http://www.internationalferryflights...X/S4010553.JPG
http://www.internationalferryflights...X/S4010554.JPG

Find A Spot For Cooling Fan Placement, (I Do Have A Guard For The Fan)
http://www.internationalferryflights...X/S4010555.JPG

Remove Lid Re Clock 180 Degrees Add Auto Tune Cap & Resister To the
Inside Of Tuner At The Terminal Connector.
http://www.internationalferryflights...X/S4010559.JPG

More Inside the SGC237
http://www.internationalferryflights...X/S4010560.JPG

Preview Of Mounting Astron Voltage Converter to lid Of SGC-237
Antenna Tuner,
http://www.internationalferryflights...X/S4010557.JPG
http://www.internationalferryflights...X/S4010558.JPG



Day-2

Drilling the vent holes for fan.
http://internationalferryflights.com...2/S4010563.JPG
http://internationalferryflights.com...2/S4010564.JPG
http://internationalferryflights.com...2/S4010565.JPG
http://internationalferryflights.com...2/S4010566.JPG
http://internationalferryflights.com...2/S4010569.JPG

SGC-237 to 706 Hookup
Manufactures Instructions I did it but put it inside the tuner.
http://www.sgcworld.com/Publications...connecting.pdf
Mine Inside The Tuner,
http://internationalferryflights.com...2/S4010575.JPG
The Molex Connector,
http://internationalferryflights.com...2/S4010578.JPG
Wiring Hooked Up,
http://internationalferryflights.com...2/S4010584.JPG
http://internationalferryflights.com...2/S4010587.JPG
http://internationalferryflights.com...2/S4010588.JPG

Mounting the Astron to the 237, Use Nylon Screws as they is high Voltage,
http://internationalferryflights.com...2/S4010581.JPG
http://internationalferryflights.com...2/S4010582.JPG
http://internationalferryflights.com...2/S4010583.JPG

Astron Mounted to 237,
http://internationalferryflights.com...2/S4010590.JPG
http://internationalferryflights.com...2/S4010591.JPG

706MKIIG Power Line Routing, to Astron
http://internationalferryflights.com...2/S4010594.JPG
http://internationalferryflights.com...2/S4010595.JPG
http://internationalferryflights.com...2/S4010596.JPG

Antenna, Connector, 3 Pin Power Connector, (Will Have Switch to Select
14V or 28V System) All protected between hard plastic. plenty of room
to connect the cables.

http://internationalferryflights.com...2/S4010600.JPG
Inside, decided to go with a thermaltake fan nice and quiet.
http://internationalferryflights.com...2/S4010602.JPG
Inside With Radio,
http://internationalferryflights.com...2/S4010603.JPG
Added And Airframe Ground,
http://internationalferryflights.com...2/S4010604.JPG

1/2' Foam,
http://internationalferryflights.com...2/S4010605.JPG

Radio Fitted with Foam Under Aluminum,
http://internationalferryflights.com...2/S4010607.JPG

Still have some wiring to do for main power and 14 Volt and 24 Volt,
Need to wire an 8pin connector under the power for remote mount
control head... Depending on if the junk store is open or not Monday I
should have it done and ready to test. May have to D sub the Control
Head. really want to use a 8pin round connector similar to the power.


BBL...



Called norvac and ordered the rest of the parts today... so it's drive
40 miles round trip traffic and snow or pay $8.00 for shipping should be
here tomorrow.

The $50.00 remote separation cable is an 8 conductor cable so I ordered
P700 And T700 microphone connectors,

http://internationalferryflights.com/HF_BOX/2399.jpg
&
http://internationalferryflights.com...X/micplugz.jpg

Possible mount under the handle or below the power cable.


Tasks today is the External fan nod to the radio to help with cooling,

Instructions here, http://www.dxzone.com/cgi-bin/dir/jump2.cgi?ID=10087

Will finish 98% of the wiring for 28V/14v system,

Wire Tune Locked LED to case

Make a fee ground straps.

Clean up kitchen table, prepare for finial assembly & testing.

Wire roof with coper wire and coax for testing, And why dose it have to
snow/rain every time I get on the roof?



Still waiting on Parts here is the Cooling Fan Mod,

http://www.internationalferryflights...X/S4010616.JPG
http://www.internationalferryflights...X/S4010617.JPG
http://www.internationalferryflights...X/S4010618.JPG

OH!! Jay, You Will get To see the Tanzinia Bird, Tanked and all when I
stop by for a night at my favorite hotel..... What room do I wanna stay in
this time? Lets See if I can sleep in them all by 2009 hahaha !!

Cool! I'll check the schedule -- we'll see if we can get you in one that
you haven't hit yet....

What day you coming?
--
Jay Honeck
Iowa City, IA
Pathfinder N56993
www.AlexisParkInn.com
"Your Aviation Destination"

On 2008-01-28, Jay Honeck wrote:
OH!! Jay, You Will get To see the Tanzinia Bird, Tanked and all when I
stop by for a night at my favorite hotel..... What room do I wanna stay in
this time? Lets See if I can sleep in them all by 2009 hahaha !!
Cool! I'll check the schedule -- we'll see if we can get you in one that
you haven't hit yet....

It's a real shame that the Amana Colonies Renaissance Faire didn't last more
than one year...or else I'd have an excuse to come and stay there.
--
Jay Maynard, K5ZC http://www.conmicro.com
http://jmaynard.livejournal.com http://www.tronguy.net
http://www.hercules-390.org (Yes, that's me!)
Buy Hercules stuff at http://www.cafepress.com/hercules-390

"Jay Maynard" wrote in message
. ..
On 2008-01-28, Jay Honeck wrote:
OH!! Jay, You Will get To see the Tanzinia Bird, Tanked and all when I
stop by for a night at my favorite hotel..... What room do I wanna stay
in
this time? Lets See if I can sleep in them all by 2009 hahaha !!
Cool! I'll check the schedule -- we'll see if we can get you in one that
you haven't hit yet....

It's a real shame that the Amana Colonies Renaissance Faire didn't last
more
than one year...or else I'd have an excuse to come and stay there.
--
Jay Maynard, K5ZC http://www.conmicro.com
http://jmaynard.livejournal.com http://www.tronguy.net
http://www.hercules-390.org (Yes, that's me!)
Buy Hercules stuff at http://www.cafepress.com/hercules-390

Renaissance Faire's, Girls in blowsy dresses or skimpy corset gown's with
chainmail, Gypsy Fire Dancing some of them events can be really fun. I have
been to a couple the first one was with a girl I picked up she was hitch
hiking she was a stilt walking human marionette puppeteer - gypsy fire
dancer she was really fun and really enjoyed the "lift" hehehehe.

I still would like to go to the Burrning Man if i ever get the chance...

OK, I am in the testing Faze!!!!


I will tell you I am really upset at Icom at this point!!! I Split the
separation cable to find out that all the wires are coated with epoxy even under
the shielding like stranded magnet wire....

Ok, 3 hours later i was able to solder an 8 pin connector to one side, About an
hour later I gave it a go on the other side it took about 2 hours very very
tinny wires. Icom just killed any repeat or future business I had with them. All
and all it worked but took way longer then expected but all connection are
mounted some finial routing of wires and she should be done.

At nearly $50.00 a cable an average hobbyist would not be able to fix the cable
if it got cut somehow.

The bolts that will hold the aluminum chassis in to the case will also be rubber
feet.


Sorry no photos tonight.... Will Post when I can need some sleep eyes are not as
good as they were few years ago and the tips of my fingers are no longer used to
the hi-temps of the soldering iron.

Icom BAAAAD BAAAD BAAAD!!! you deserve the Chinese or Koreans to make clones of
your cables!!!! maybe now your radios!!!

On 2008-01-30, NW_Pilot wrote:
I will tell you I am really upset at Icom at this point!!! I Split the
separation cable to find out that all the wires are coated with epoxy even under
the shielding like stranded magnet wire....

Ok, 3 hours later i was able to solder an 8 pin connector to one side, About an
hour later I gave it a go on the other side it took about 2 hours very very
tinny wires. Icom just killed any repeat or future business I had with them. All
and all it worked but took way longer then expected but all connection are
mounted some finial routing of wires and she should be done.

Hm. Have you looked at the FT857? Its extension cables use standard,
crimped-on modular connections, 4 pins for the control head and 8 for the
mike.
--
Jay Maynard, K5ZC http://www.conmicro.com
http://jmaynard.livejournal.com http://www.tronguy.net
http://www.hercules-390.org (Yes, that's me!)
Buy Hercules stuff at http://www.cafepress.com/hercules-390

Ok, the guy with the bouncing e-mail the model of Astron is N2412-24 I tried
another model that peek's @ 20amps it would not run the 706MKIIG above power
level 5. Spend the money and get the model I have listed. There may be others
but Astron is a good quality unit.

Model N2412-24
Input Voltage 22-32 VDC
Output Voltage 13.8 VDC
Line/Load Regulation .04 VDC
Ripple 20mVrms
Continuous Current 20 Amps
Peak Current 24 Amps
Overvoltage Protection16 VDC
Efficiency 88%
Dimensions 2" x 6.2" x 7"
Weight 2 Lbs


Here is the factory Image
http://www.astroncorp.com/images/N2412-24gif.gif

Astron Site,
http://www.astroncorp.com/dcdc.shtml

It's powerup and test were ok, doing finial assembly will take photos tomorrow.

Decided to not wire it for 14V as of now need to work a few issues out with
switching.

Here Are The Completed Photos,

Inside Wired With Pad. I Ended up drilling a number of holes under the side edge
lip for Air and under the front I routed it out behind the name plate lots of
air. Fan was Wired to Radio Out 12V so when radio is on fan is on fused with a
..5 amp fuse inline. Temperature while in Use is acceptable Levels High Volume
Computer Fan

http://www.internationalferryflights...T/S4010621.JPG

Connector Side Of Unit,

http://www.internationalferryflights...T/S4010622.JPG
http://www.internationalferryflights...T/S4010623.JPG

Left to Right,

Ground.

2 Connector Left Of Fan
Bottom is Power 3 Pin, 14V, 24V, & Ground (Eliminated Need For Switch And Slaved
Ground to System Ground)
Top Is Remote Head Mount 8 Pins,

Fan

Right Of Fan

Top Is Antenna,
Bottom Is Tuner Locked LED

Inside,

Antenna, Tools, Cables, And Connectors. (Pill Bottle is For Small Parts)
http://www.internationalferryflights...T/S4010624.JPG
http://www.internationalferryflights...T/S4010625.JPG

Radio Control Head is Mounted In Foam, 1/2" Sides 1" Back 4" Front

All items except tool kit are held in with 3M wire wrap like double sided Velcro
hot and glued in place..

Inside Full Padding, HF Has Velcro on the Top To Mount Mic.

http://www.internationalferryflights...T/S4010627.JPG


Complete Unit,
http://www.internationalferryflights...T/S4010629.JPG

When Closed this unit should withstand shipping as is and airport baggage
handlers if checked.

Now its simple to hookup, and repack should be a 5 min install on a single
engine Cessna!!!

The End!!! Yea, Right It's a HAM!!!