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