[TowerTalk] Homebrew tower...

[Joe Subich, W4TV]

30+ years ago Wilson had tower sections made of something very
much like 1 1/4" conduit, flattened at the ends, and bolted.
They were "straight" so they needed to be guyed and climbing
would be an issue.  Construction was similar to the picture -
but the overall diameter was on the order of 16".

The tower was light enough that 40' or so could be walked up by
one or two people and IIRC it would probably be possible to erect
40' - 50' with a Hexbeam in one piece using a gin pole or falling
derrick.

73,

    ... Joe, W4TV


On 2015-06-26 11:05 PM, Jim Lux wrote:
> On 6/26/15 5:16 PM, Richard (Rick) Karlquist wrote:
>> See:
>>
>> https://www.flickr.com/photos/18794861@N00/2340109594/
>>
>> The "Mirador"
>>
>> About 8 years ago when I was at the "Maker Faire"
>> (by Make Magazine) there was an exhibit of a
>> tower made out of electrical conduit.  Each
>> conduit had the end flattened with a hole
>> drilled through it.  <snip>
>
>> something like 5 feet.  I guess this guy assembled
>> the whole thing in situ at the Faire!  He told me
>> there is some machine tool he used (it had a weird
>> name) that could either flatten or punch holes in
>> the ends of the conduit.
>
> A Piranha? (that's a trade name).
>
> I built a geodesic dome out of conduit.  Engineer hammer to smash the
> ends (faster than crushing in a vice), drill press to drill the holes:
> you need sharp bits and a jig to make the holes be in the center: don't
> try it with a hand held drill.
>
>
>
>>
>> The tubes you have sound like "3/4 inch" water
>> pipe.  They are going to be more difficult to flatten
>> and drill at the end than conduit, which is designed
>> to be formed.
>
> conduit splits when you crush it: the seam weld is really weak.
>
>>
>> Unfortunately, it is dangerous to weld galvanized
>> material, so you have to fasten it together with
>> bolts.
>
> Do the welding outdoors with the wind at your back, and the zinc fumes
> go downwind. A nice strong fan helps too.
>
> The welders in the effects shop wouldn't weld galvanized indoors, but
> outdoors was ok, for small stuff (up to 2" diameter kind of stuff).  The
> structural welders (welding things like 8" beams) would use blowers and
> still hated doing it.  But there's a lot more zinc on a galvanized I
> beam than there is on galvanized fence rail.
>
>
>
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