Antenna Insulator
Home
You can make
your own antenna
insulators for less
than $1.00 each.

The beauty of it is
that they look
awesome,
intimidating,
maybe even
outright
frightening.

I cut an 8" length
of 3/4" PVC pipe,
which is about 1"
outside diameter.

Then I cut out 5
disks from 1/8"
fiberglass sheet
(or ABS plastic)
about 3" in
diameter with a
hole saw. Each
disk was then
bored through the
center with a 1"
hole saw.

I slid the disks
onto the pipe and
evenly separated
the disks by
wrapping 1" wide
masking tape
around the pipe in
between them. A
final wrap of tape
outside of each
end disk makes
the assembly
stable and secure.

I mixed about 4
ounces of marine
epoxy in a coffee
can and inserted
the insulator. With
a small paint
brush, I drizzled
the epoxy over
the entire
assembly. Then I
removed the
insulator, turned it
up side down and
repeated the
process.

Once completely
soaked, I removed
the insulator and
hung it
horizontally to
allow the epoxy to
cure.
About every 5
minutes, I gave
the assembly a 90
degree turn to
allow the epoxy to
"settle" evenly.

Once cured, I
drilled a 1/4" hole
through the pipe
1" back from both
ends. In each
through-hole I
fastened a
stainless steel 1/4
x 20 bolt and lock
nut. I used cap
bolts which only
have threads on
the ends.
Warning: If you live in an apartment or condo, or any place with antenna restrictions, this isn't the project for you.
I really made these because the antenna wire I had just acquired wouldn't fit through the holes of any of the
ham-type insulators I had. I wanted my 80 meter dipole to stay up where it belonged, through any weather that New
England's Mother Nature could dish out, up to and including hurricanes and ice storms. The antenna wire is
telephone drop wire. It's the stuff that feeds your home from the utility pole out by the street. This stuff is super
strong and is worthy of a suitably stout insulator. The 1/4" cross bolts provide a nice smooth surface to loop the wire
and the rope through for fastening to the insulator. I also used Dacron (polyester) rope. The assembly is rigged with
pulleys and weights to keep the wind-blown trees from stressing the antenna's components.
See the "Betts Method"
antenna page. I have spent too many cold, freezing, icy days repairing downed antennas. When it's the middle of
March and I'm on 80 meters in a nice warm shack ... I want to stay on 80 meters in that nice warm shack.
The photos above don't do the entire thing justice, but at least you can get some ideas on how to build an antenna
that stays up.
Plus it really looks cool!
Counter