Ham Station in

a Tool BoxGREG SHUSTER KI7DTS

AUGUST 7, 2020

This Presentation

This presentation is more “Mechanic Illustrated”

Less “whys” and “wherefores”

It covers the high points of the build

Not every detail

It can be used as a starting point for a build of your own

Safety First

If your not comfortable using power tools

Team up with someone who is

Or build it with the tools and skills you possess

Why?

CCARC Vice President Jeff Hildebrand asked me to photographically document the creation of a ham station in a tool box

Project aimed at hams with limited space, i.e. apartments and condos

For a future Club meeting presentation

That led to several meetings to discuss design concepts and component selection

Then COVID-19 and the meetings ceased

Jeff went in his direction and I went off in mine (the Great Schism)

My evolved goal is to have a station I can take with me and operate anywhere

Baseline Deign

Utilize a 22’ RIDGID tool box

Don’t compromised the box’s dust and water resistant features (no holes)

Easy to build (maybe I slipped a little here)

120 VAC power

Easy and quick set-up and operation

Inspiration

Looked at Hardened Power Systems Commander 7100

Ammo can go box

Really just a radio and power source

Not a complete station

$725 plus the radio

Build a rack system in the box

Discovered Feature

While conceptualizing the project, Jeff and I discovered

that the box lends itself perfectly to a small ham station

When opened and lying on its back

Lower box affords

A natural viewing angle of components

Enough volume and depth to house all components

Lid makes a convenient desk surface

Remove clip from hinge to

achieve greater that 90

degree opening of lid

Good ergonomic

angle

Prototype 1

Boiler plate

¾” scrap wood, one shelf, wood screws

Tool box has molded in feature that will hold the base

plate of an internal rack system in place

Overhang locks into molded

feature in tool box

Jeff wasn’t enthusiastic, the “Great Schism” happed here

Prototype 2

Single shelf like P1

3/8”plywood, 5 layer

1/16” x 1” aluminum angle

aluminum corners

Pronged “T” nuts and 8-32

machine screws & washers

Pronged “T” Nut

Design Flaw

Notice, all the angles and screw heads are internal

Impossible to assemble rack after populated with

components

All angles and

screw heads face inward

Prototype 2

Top and bottom angles moved outboard

Added second shelf after components were selected

Needed more real estate

Top and bottom angles

moved outboard

Top and bottom angles

moved outboard

Dimensions1

0.5

”

18.875”

1368 Cubic InchesInternal Volume

418.5 Square Inches

Shelf Area

Component Selection

ICOM IC-7100 transceiver

I liked the form factor

Covers HF/UHF/VHF, all modes

MFJ-901B Manual Antenna Tuner

Considered LDG auto tuner but was out of stock everywhere

901B can accommodate coax, balanced line and random wire antennas

MFJ-884 HF/UHF/VHF, SWR/Watt Meter

I’m a meter guy, necessary for manual tuner

MFJ-4230MV 30 Amp Power Supply

Smallest 30 Amp power supply available

MFJ-281 Speaker

(Maybe I should have asked MFJ to sponsor the build?)

Component Mounting

Components were hard mounted with aluminum angles

Existing component case fasteners were utilized

Didn’t want to drill into new components

Used OEM mobile mount for radio’s main unit

Fastened to shelves with “T” nuts and machine screws

Final Component Layout

Speaker

Power Supply

Connector Bracket

SWR/Watt Meter

HF Antenna Tuner

IC-7100Main Unit

Rack System

Middle shelves cut back ¾” for better access to knobs

Radio Head Unit

Cubby

Microphone Cubby

Wiring

Probably most

challenging part of

build

Lack of coax flexibility required

large bend radii

Slotted holes in

shelves facilitated

routing

Generous use of tie

wraps kept things tidy

beforeafter

It’s Done

Rack system can be removed from the tool box and used like this

In the Box

Unit weight; about 33 pounds

Left to be Done

Build padded cubbies for radio head unit and microphone

Fab and install a full size desk top into box lid

Rebuild wooden parts with high grade European plywood

Domestic plywood exhibited some warpage after cutting

Research portable antenna systems

Project Cost

ICOM IC-7100 transceiver – HRO - $849.95 (after rebates)

MFJ-901B Manual Antenna Tuner – HRO - $109.95

MFJ-884 HF/UHF/VHF, SWR/Watt Meter – HRO - $124.95

MFJ-4230MV 30 Amp Power Supply – HRO - $99.95

MFJ-281 Speaker – HRO - $18.95

ICOM IC-MB62 – Radio Mount - $35.95

Tool Box – Home Depot - $39.00

Plywood – Home Depot - $13.56

Aluminum Angle – Home Depot - $19.15

Fasteners – Amazon, Park Rose Hardware - $18.92

Cables/Wire Harness/Connectors – Amazon - $70.32

Total - $1261.65 (plus tax) (give or take)

Construction Notes

Tools Used (if you got them, use them)

Table saw - cut plywood

Drill press and vice - drill holes in plywood and aluminum angle

Band saw - cut aluminum angle

Stationary disc sander - square up aluminum angles

Small clamps - hold pieces together for match drilling

Misc. hand tools – files, screw drivers, pliers, wrenches, squares & measuring devices, etc.

It could be built with a power saw, drill and hand tools

It would take longer

Results would probably be rougher

Construction Notes

When drilling plywood, clamp drilled

angles and use as drill guide

IMPROTANT

Extensive match drilling will introduce

tolerance buildup

Not all hole sets will be interchangeable

Number each angle and wood pair

when drilled to insure proper reassembly

There are 48 holes in 16 groups that

need to line up for accurate assembly

Drilling

In lieu of extensive drill fixturing, match drilling was used

Initial hole layout was done on one angle

First angle was drilled

Subsequent angles were clamped and match drilled using original as a drill guide

Match drillingtwo angles

Construction Notes

Fasteners

8-32 pronged “T” nuts

Creates machine threads in wood

Flush on one side, almost flush on the other

Easy to install

Very secure and facilitate multiple assembly and disassembly

½” x 8-32 machine screws

#8 flat washers

All purchased in bulk (100 pieces) from Amazon

Much cheaper than local hardware store

For Consideration

Purchase the lower/wheeled tool box and build it into the

power source for the system

Power supply

Batteries

Battery charger

Solar controller

Wires & accessories

For Further Consideration

Purchase all 3 boxes of the system

Accessory box$29.00

Radio box$39.00

Power box$59.00

Questions?

Specific dimensions are available from the author