Tag Archives: ICE lightning arrestors (Morgan Manufacturing)

2015/08/05 (W) No Mask Wednesday

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Linda was up at 6 AM and left for the bakery around 6:20 AM, I think. I was more asleep than awake and did not get up until later. I wanted to do a load of laundry but needed powdered detergent which I did not have. I also needed to make a run to Lowe’s so I left to take care of my errands without making coffee or having breakfast.

I picked up a couple of 2x4s at Lowe’s that I will use to cut a pair of support arms for propping open the fixed window in the bus while we exchange the refrigerators. I was going to buy a 4’x4′ (half sheet) of plywood to cut for the base of the refrigerator alcove but did not care for the selection. I also did want to wrestle with the size and weight by myself. I will have to go back to The Home Depot with Linda to get what I need. I got my laundry supplies across the street at Meijer’s and headed home.

After unloading the 2x4s I thought I would program the remote control in my car for the new garage door opener. The procedure is very simple but much to my dismay the remote would not connect with the opener. The remote is a 3-button model made by Chamberlin, and both garage door openers are identical Chamberlin models. We have four of these 3-button remotes, one for me, one for Linda, and one for each of our children. We got the 3-button model because we have two overhead doors on our garage and plan (hope) to have a barn someday with an overhead door. All four of the 3-button remotes programmed to the large garage door without a problem and the new door opener came with a single button remote that works just fine, as did the large garage door opener. I won’t know if the problem is the opener or my remote until I can try programming Linda’s remote. If her remote will program then I know it’s my remote, but if it won’t program I still won’t know where the problem lies.

I had originally planned to mask off the interior of the bus today so I could start sanding the floor tomorrow but decided to put it off. Not only would the painter’s plastic be difficult to manage by myself, I realized that it did not make a lot of sense to tape it up in advance of doing the refrigerator swap. I was on the phone with Chuck arranging to bring our bus to his shop this weekend to take care of the refrigerators when our USPS carrier, Michelle, came to the door bearing gifts. Well, OK, they were packages, but I did not expect them until tomorrow so that made them more like gifts in my mind. One was from Amateur Electronics Supply (AES) and the other was from Morgan Manufacturing, so it was all ham radio stuff.

I went to my ham shack/office and mounted the control head for the Yaesu FTM-400 on the stand that just arrived from AES. I e-mailed Steve (N8AR) to arrange a time to test the lightning arrestor before installing it in our cable entry box. I then e-mailed Jarel to start trying to arrange a day next week to drive to his shop in Logansport, Indiana to pick up the custom walnut desk. Finally, I e-mailed Josh at Coach Supply Direct to make sure he was going to be around. I was checking out the TVFool.com website, which Steve recommended, when the art frame shop in Howell called to let us know that three of our four paintings were ready to pick up. They would have all been done but he ordered the forth frame the wrong size and had to reorder it. Linda then called to let me know she was on her way home from the bakery. So much communication, so little time.

When Linda got home we discussed going out to dinner and researched a new place that had opened in Howell. As usually happens, however, there is almost no place that serves anything we choose to eat and we ended up staying home. Linda had a couple of Boca burgers in the freezer and we had those with corn-on-the-cob and fresh fruit (peaches, nectarines, and strawberries). We eat better food, and in smaller quantities, when we dine at home.

After dinner I caught Steve (N8AR) on the radio and we agreed that I would bring the lightning arrestor over to his QTH at 8 PM. I had an e-mail related to the draft of the July issue of Bus Conversion Magazine and checked to make sure a correction had been made correctly.

At Steve’s house my lightning arrestor tested better than the previous one, and should work OK in my system, but it was very clear that there is something wrong with the design and/or manufacturing of these VHF/UHF I.C.E. units. We also came to the conclusion that the quality control testing the manufacturer was doing (if any) was inadequate to reveal the problem. I expect, however, that this one will work when I install it so if it is typical of their units most hams would not have a reason to suspect that it was flawed. Someone would have a problem with it, however, as it is clearly not usable for all frequencies from 40 MHz to 1 GHz as stated on the label. My unit has a 0.31 dB loss at 445 MHz (it should be 0.01) but has an 11.59 dB loss around 635 MHz, which is a huge factor of 16 times loos of signal, and the loss from 500 MHz to 1 GHz is unacceptably large making it useless in that range of frequencies.

Steve captured all of the data and e-mailed it to me. He then tested one of his Polyphaser lightning arrestors and sent me that data file. He also sent me the link to the VNWA software from SDR-Kits.com that I needed to work with the data file. We spent a few minutes talking about the problem we are having at home with our ham radio transmissions interfering with our OTA TV signals. He sent me a link to the free student version of the ELSIE (“L”,”C”) filter design software.

I left about 9:45 PM and called my friend, John Rauch, to see if Saturday noon would work for him in terms of our refrigerator swap. He said it would and that he would check with his son (also John) to see if he could/would also help. I will let Chuck know tomorrow that it looks like Saturday is a “go.”

Linda was asleep by the time I got home so I worked in my office until after midnight. I captured the data attached to the e-mails from Steve and then downloaded and installed both the VNWA and the ELSIE software. I then uploaded my personal blog posts for June 28, 29, and 30. I logged in to the FMCA Freethinkers website, the FMCA GLCC website, and the SLAARC website and installed updates for the themes and numerous plug-ins. With that I came back upstairs and worked on this post in the living room so as not to disturb Linda and finally went to bed around 1 AM.

 

2015/07/16 (R) RV Work

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We were up at 6 AM and by 6:25 Mara had started the engine of her motorhome to pull in the slides.  She disconnected the electrical cord and we helped her back out of the driveway at 6:40.  She was pointed west so she had to drive to the end of our street and use the circle to turn around.  Her destination was Cummins Bridgeway in New Hudson.  When she made the appointment they said the closer to 7 AM she could arrive the better.  They estimated she would be there 3 to 4 hours.

Mara's Fleetwood Bounder parked in our pull-thru driveway.

Mara’s Fleetwood Bounder parked in our pull-thru driveway.  Linda in green jacket, Mara in red.

Linda did not sleep well last night, a common side effect of eating too much too late in the evening, and went back to bed once Mara was safely on her way.  I decided to stay up and clean the coffee maker before making coffee.

I wiped out the upper housing and cleaned the nooks and crannies with Q-tips.  The upper housing is undoubtedly designed the way it is to make it structurally adequate with a minimum of plastic but it was equally obviously not designed with any consideration for being able to clean it.  Like many things, it leaves me wondering if the designers ever use the products they design or what sort of functional specifications they work from and who develops those.  I think the Bauhaus had it right when they declared “form follows function.”  My guess is that commercial equipment, while less “stylish” than consumer goods, has cleanability and serviceability as primary design considerations.

I remembered that we had a one gallon jug of distilled white vinegar in the bus so I got that and ran eight cups of it through the coffee maker.  I added four cups of water to the used vinegar and ran it through again.  I then ran 12 cups of RO water through the coffee maker.  By the time I was done it was approaching 8 AM so I ground up some of the Sumatra Mandheling beans (not decaffeinated) and made seven cups of coffee.  I normally make 8 – 9 cups but this was full-strength stuff.  I’ve been making 11 cups while Mara is here but it turns out that she does not drink much coffee so I will be back to my usual 8 – 9 half-caff servings going forward.

I enjoyed my first cup of coffee while finishing yesterday’s blog post and starting this one.  I enjoyed my second cup while researching hardware for mounting a small table to a wall so that it is essentially cantilevered, which is the table arrangement we need for the bus.  I found a 2-piece aluminum extrusion that might be the solution for attaching the table to the wall.  It is 30″ long and can be cut to length but I do not think it will not be strong enough by itself to support the table.  I found an angle bracket on Rockler that might be the additional piece I need.  It is 12″ x 18″ with a notched corner, made of 1/8″ steel, and powder-coated black.  A pair of them will support 1,000 pounds so one in the center would be more than sufficient.  An alternative would be a wood strut angling back to the wall but we are not willing to have a vertical table leg.  I have not decided whether the table should be removable but I am leaning towards a more permanent installation.

Linda eventually got up but neither of us were hungry so we did not have breakfast.  I went to my office and ordered the ZioTek monitor mounting system from CyberGuys.  I then e-mailed Ewa at AFC Industries and thanked her for the second quote but let her know that the price was way out of my budget.  I finally settled in to work on the custom desk design for the bus and eventually finished it (I think).  Linda left around 12:30 PM for her dermatology appointment.

Now that we have base station antennas cabled to the ham shack I tend to have the new Yaesu FTM-400DR/DE dual band (VHF/UHF) radio on whenever I am working in my office.  It provides a pleasant diversion from my other tasks and is actually useful.  Somewhere mixed in with everything else were a couple of QSOs with ham buddies and an attempt to coordinate with Steve (N8AR) and Mike (W8XH) about testing my two Morgan lightning arrestors at Steve’s QTH.

This toad was sitting on a rock by our front porch.

This toad was sitting on a rock by our front porch.

Our bus had settled in the rear and was clearly out of level.  The reason it had settled was that I forgot to switch the suspension system to Level Low and shut off the air to the engine accessories.  It was of no consequence but it bugged me so I started it, let it air up, re-leveled it, shut it down, and switched off the batteries and engine air accessories.

Mara returned from Cummins Bridgeway around 1 PM and I guided her back into her parking spot.  They did the routine service on her motorhome engine and generator but found several things on the genset that needed to be repaired.  She agreed to have the work done so they removed the genset from her rig and will reinstall it next Wednesday.  They also inspected the motorhome and gave her a list of other things that needed to be fixed, some right away and some eventually.  She did not have them do any of that work as she wanted me to look at the list first.  The added service work means Mara will be visiting with us for at least another week, which pleased us greatly.

I went over the list with her and we discussed the relative importance and urgency of each repair.  One of the items involved the caulking on the roof so we both climbed up there to have a look.  I also wanted to scope out how we might install her weBoost Drive 4G-X cellular booster system.  While we were on the roof I was able to rock the rig side-to-side quite a bit just by shifting my weight.  One of the other items on the diagnostic list was shock absorbers and I indicated that I thought that sounded appropriate, especially given that the back ones reportedly had cracked/broken mounts.  They also noted that the transmission fluid was low and that the filter and fluid should be replaced.  I encouraged her to have these taken care before she left as Cummins Bridgeway is a very good service facility.

The other items were things that could wait but the caulking of the roof was something Mara could do herself.  She likes to take care of as much of her rig as possible and she will be here through at least Wednesday, so she has time.

Linda got back from her out-patient surgical appointment with bandages in seven different places.  We visited for a while and then I left the ladies and returned to my office.  I started on the design of the pull-out pantry for the bus and quickly realized that the very expensive Fulterer heavy-duty pull-out pantry slide I ordered from Rockler was too wide for the space we have available.  I came upstairs and groused about it for a while until Linda and Mara urged me to try canceling the order.  I called Rockler and spoke to someone in customer service.  I won’t know until tomorrow at the earliest, and probably not until Monday, if I was successful in intercepting the order before it shipped.  If not I will have to pay to ship it back and may have to pay a restocking fee.  Although I do not have anywhere else I can use it at the moment, between the restocking charge and the cost of shipping I may just keep it and find a use for it.

Linda made a large salad for dinner and we chatted during and after the meal.  It had been an early, long, hard day for all of us.  Mara returned to her rig before it was dark and Linda headed off to bed shortly thereafter with me not far behind.

 

2015/07/08 (W) Custom Desk Design

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Linda continued to research Florida RV parks this morning over coffee.  Riverside RV Resort which was fully booked but she found Big Tree RV Resort in Arcadia, Florida.  It is located in a similar part of the state and Arcadia is where the annual Arcadia Bus Rally is held between Christmas and New Year’s.  Big Tree is a Carefree Resort, which means they had a nice, professionally done video on their website.  We checked it out on Google Earth and it looked OK.  Hey, the entrance is right across the street from a Walmart, so the shopping is convenient.

Linda called Big Tree and talked to Pat.  They only had five openings for the 2015/16 winter season so we reserved a spot for January and February 2016 with the understanding that we can probably extend through March if needed.  First, however, we want to see if we can find someplace else to stay in another part of Florida for March and perhaps some of April.  We would like to spend some time in northeast Florida.  Our friends, Pat and Vicki, spend late February and early March at Jetty Park near Cocoa Beach and Cape Canaveral.  Besides their presence there is a lot to see and do in that area, so that is appealing to us.  However, the spring FMCA national rally will be in Perry, Georgia the third week of March, so we are being pulled in several directions.  Such is the RV life; so many places, so little time.

Breakfast was cinnamon raisin toast and fresh melon.  After breakfast I called Chuck It Junk Removal and left a message that we would like to rent their dumpster trailer for starting on Monday 20 July with pickup on Friday 24 July.  Brad called back and said those dates would work for him.

Linda continued to research RV parks in Florida for December and March.  She called Williston Crossings to ask about space for December but the lady on the phone said someone else would have to call us back.  As much as we liked Williston Crossings the winter before last we wanted to spend the heart of the winter farther south in the state.  A more southerly location would afford us a warmer climate and position us to explore a part of the state we did not see last time.  It would also put us closer to many of our friends who winter in southwest Florida.  We really enjoyed the southwest Arizona climate this past winter and have talked about trying a winter in southern Texas and/or southern New Mexico.  I have no doubt we will visit those areas in future years but this year we wanted to return to Florida.

I typed up a short letter to go with the defective Morgan M-302N coaxial cable lightning arrestor and boxed it up for shipping back to Morgan Manufacturing in Martinsville, Indiana.  Linda got a new 90-day prescription for me when she saw the dermatologist yesterday so we also got that ready to mail.  She then left for the library, post office, and grocery store.

My focus for the rest of the morning was on uploading posts to our personal blog but before I even got started I discovered a mouse at the entrance to the utility area in the basement.  It had not survived its encounter with one of our cats, probably Juniper, so I put it in a small zip lock bag and put it in the trash.  I know that food and shelter are powerful attractions for mice but I am surprised that the presence of two cats in the house is apparently not a deterrent for them.  Other than the one mouse we live trapped in the bathroom the mice are not taking the bait so far.  Indeed, it may be that we are luring them out of hiding and Juniper has figured out where to lie in waiting to ambush them.  From what we have seen she is a very skilled, and determined, mouser.

Linda went for a walk as soon as she got back from running her errands.  By the time she returned and prepared tofu hotdogs for lunch I had uploaded eight blog posts covering June 8 through 15.  After lunch I sent an e-mail to a dozen or so folks letting them know where we would be this winter.  I then got to work on the design for the custom desk.  Except for a dinner break I worked on it until 9 PM when I quit for the day and went upstairs to watch the final episode of The First Peoples on PBS.

Butch and Fonda are at the Crosley Automobile Club national gathering in Wauseon, Ohio this week and will be back home on Sunday.  I would like to have the design for the desk and other custom woodwork done by this Sunday so I can drive it down on Monday or Tuesday next week, give it to Jarel Beatty (the cabinet maker), and visit with Butch and Fonda before heading home.  The desk will take some time to build and I would like to take the bus to Butch and Fonda’s in August before they leave for Arizona so Jarel can bring it to their place and help me install it, assuming, of course, that I have the new floor installed by then.

The desk is proving to be quite challenging to design but after thinking about it for the last couple of weeks I had several “breakthrough” ideas today.  One was to turn the printer 90 degrees so it faces fore and aft rather than side-to-side.  Another was to leave the front of the printer box open and cover it with a swing up work surface.  But the basic difficulty I am having is figuring out how to draw it.  I finally decided to draw a plan view of the base which really helped me see where the Aqua-Hot fan-coil heat exchangers will go and how the coolant lines will run.  I still have a lot of work to do, and I really wish I had AutoCAD (and knew how to use it), but I went to bed feeling like Sunday was a realistic target date for this piece of the project.

 

2015/07/06 (M) Arrested

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Our morning started with coffee, once we got up, and then granola for breakfast.  We are both in better health, generally, than we were in our 30s, 40s, and early 50s, but having Madeline here requires a different kind of constant energy and attention and we are somewhat tired by the time her parents take her home.  It’s a good tired, of course, but we were still tired this morning and slept in for a while.

I had hoped to get back to work on the bus today but the afternoon highs were forecast for the mid-80’s which would make for less than comfortable working conditions.  The forecast for the rest of the week was for highs in the 70’s so I decided to wait another day.  I really needed to get back to work on the bus but I also had other things to take care of that seemed at least as pressing.

At the top of my list was the SLAARC website.  Scott Neader had successfully copied the SLAARC WordPress website from GoDaddy.com to QTH.com and changed the domain pointers to point to the QTH servers.  He needed me to check that everything was working correctly.  He was also preparing to transfer the domain name registration and needed my involvement for that process.

Part of our home ham radio shack with the new Yaesu FTM-400 2m/70cm mobile radio shown lower left.

Part of our home ham radio shack with the new Yaesu FTM-400 2m/70cm mobile radio shown lower left.

Continuing with the ham radio theme, I needed to resolve how I was going to mount the new Diamond X-300NA 2m/70cm antenna and possibly remount the outside omnidirectional antenna for the cellular booster system.  That meant doing some minor engineering and possibly ordering parts.  I was also preoccupied with the fact that I was unable to participate in the SLAARC info net last night, apparently due to some malfunction in our ham radio system, and it was going to bug me until I figured it out.

Last, but not least, was the fact that I was now one month behind on uploading posts to our blog.  The farther behind I get the more of a chore it is to get caught up.  Like cleaning up my e-mail inboxes, which I also need to do, it finally becomes “the” thing I “have” to take care of before I can concentrate on any other work.  I hate it when that happens, but it is a recurring problem and I have no one to blame except myself.

I often seem to spend the first part of each morning finishing up my blog post (draft) for the previous day and outlining the one for the current day or making notes for future days.  It’s my way of reflecting on what I have done and thinking ahead to what I need/want to do next.  By the time I actually got to work this morning it was after 10 AM and Keith showed up to cut the grass.  It did not rain this past week and he was finally able to cut the grass at the west end of the property, which is low and often wet.

Before going to my office I checked the rebate paperwork which Linda had assembled for the new Yaesu ham radio and got it ready to mail.  I also started filling out the prescription form to send in to Catamaran Home Delivery when I realized the doctor had written the Rx for 30 days instead of 90.  I called the clinic and they said it would (probably) be OK to have Linda bring it to her appointment tomorrow and have the doctor rewrite it.

Our coaxial cable adapter kit.

Our coaxial cable adapter kit.

When I finally got to my office I looked at the SLAARC WordPress website on my computer to make sure everything was working.  The only thing that was not working was an online tool for logging check-ins for the Sunday evening info net.  I e-mailed Scott about that and then logged in as an administrator and updated several plugins.  I logged in to the FMCA-GLCC website and updated it and then did the same for our personal website.  I then created a support ticket at iPower.com regarding the broken FMCA Freethinkers website.  I dealt with SLAARC related e-mails throughout the day.

I spent the rest of the morning editing blog posts for the second half of June and early July and then started selecting and processing photos to use with blog posts, and processed those further.  By the time I quit working I had photos ready for everything except the three days of the ARRL Field Day event.

It was a nice day, if a bit warm, and we had the house opened up including the basement doorwall.  Other than a short break for lunch by 2 PM I had sat long enough and decided to setup the new Diamond X-300 2m/70cm antenna on a temporary pole.  I rummaged around the garage and found the four section pole I had used at the old house.  The pieces were buried under a pile of GLCC related PVC flag pole sections but I was able to slide them out.  I cleaned up the swaged connections and used a light coating of anti-seize compound before assembling them.  I stood it upright on the ground at the NE corner of the deck and zip tied it to the corner post at three points.  I then set up the 7-foot step ladder on the deck and removed the upper two sections.

The new Diamond X-300NA VHF/UHF ham radio antenna is visible atop the pole at the corner of the deck.

The new Diamond X-300NA VHF/UHF ham radio antenna is visible atop the pole at the corner of the deck.

I unbolted the X-300 antenna from its storage place on the side of the 40-foot tower and set the base on the east deck railing.  I then got one of the 35-foot heliac coax cables from the basement and attached it to the feed point of the antenna.  With Linda’s assistance I mounted the antenna to the top of the topmost mast section and zip tied the coax to the mast.  Back up on the ladder I was able to slip the upper mast sections into the lower mast sections and add a couple more zip ties to secure the coax.

I routed the coax over to the cable entry box (CEB) so that it was not visible.  The antenna is shielded from view by our Norway Crimson King Maple tree and the mast is very inconspicuous; not bad for a temporary installation.  I disconnected the X-50 antenna coax from the Morgan UHF/VHF Lightning Arrestor in the CEB and attached the coax from the X-300 in its place.  I went back to the ham shack, turned on the Yaesu radio, and listened.  Nothing.  I tried calling the South Lyon 2m repeater but nothing came back.  I tied the Novi 440 MHz repeater…nothing.  I turned the radio off and moved the coax to our Icom IC-7000 radio and repeated the tests.  Same results.  Something was clearly wrong so I called Mike (W8XH) to see if he could help me figure it out.

Mike was out but on his way back home and called me when he was back at his base station.  We verified the transmit and receive squelch settings on my radios and then tested both antennas on both radios.  Using our cell phones we confirmed that he was not hearing my transmissions and I was not hearing his, either direct (simplex) or through the repeaters.  It was now clear that RF signals were not making it into or out of my system and there was one component that was common to all configurations; the Morgan M-302N VHF/UHF Lightning Arrestor.

I have a coaxial cable adapter kit that allows me to temporarily interconnect most of the connectors used in amateur radio coaxial cables.  At Mike’s suggestion I used the kit to assemble an adapter (barrel connector) with N-female connections on both ends.  I then disconnected the antenna and radio coaxial cables from the lightning arrestor and connected the radio coax directly to the X-300 antenna coax.  Back in the ham shack I tested this configuration with both radios on both repeaters.  I was receiving both repeaters with S7 to S9 signal strength, which is good, and very little noise, which is also good.  Mike reported that my signal was very strong into both repeaters and that he was receiving me full-quieting.  I shut the radios off and then switched the connection in the cable entry box to the X-50 antenna.  We repeated the tests with the same results, confirming that the problem as the lightning arrestor and only the lightning arrestor.

The current status of the cable entry box.

The current status of the cable entry box.

Although I was disappointed that the M-302N was defective I was overjoyed, or at least relieved, that everything else was working perfectly.  Although the new X-300 antenna turned out not to be “necessary” having it on a mast above the tower will give us an even better transmit and receive capability than the current X-50 installation.  I even have some hope of being able to reach repeaters farther away in the Detroit metro area as well as in the Lansing, Flint, Ann Arbor, and Ypsilanti areas, and perhaps much farther beyond.  Windsor (Canada) and Kalamazoo are possible when atmospheric conditions are right for longer range propagation, and the Saginaw, Mt. Pleasant, Fort Wayne (Indiana), and even Cleveland (Ohio) areas are not out of the question.  Once, at the old house, I was on the Spirit of 76 repeater atop the Renaissance Center in Detroit when it picked up a 2m station from Iowa.

Relieved of my concerns, especially about the operation of our new radio, I returned to my computer-based tasks.  The first thing I did was e-mail Chris Perri at KF7P Metalwerks regarding the lightning arrestor, which I purchased from him as part of the cable entry box.  He apparently forwarded my e-mail to Morgan Manufacturing Inc., or at least e-mailed them, as I got an e-mail from Bob at Morgan with instructions on where to return the unit.  It has a lifetime warranty and he indicated they would repair or replace it as needed.

I spent the rest of the afternoon and evening, except for dinner, working on photos.  Dinner was chickpea salad on a bed of greens with steamed baby bok choy dressed in rice vinegar.  It was a perfect meal for a warm summer evening.

The humidity had been up all day and rose as the temperatures dropped at sunset, although they did not drop much.  Linda was watching an episode of Scorpion when I finally came upstairs.  We watched an episode of NCIS Los Angeles after that and then an episode of Two and a Half Men, which I have always enjoyed.  We turned on a small fan but it was a warm, uncomfortable evening for sleeping.  For whatever reason we did not turn on the air-conditioner although in hindsight we should have.

 

2015/06/20 (S) Cable Entry Box

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We had not been to our local ham radio club breakfast the last two Saturdays because of the GLAMARAMA rally and a visit from Linda’s brother, Ron, and his wife, Mary.  The club was conducting VE testing today, rather than the usual 4th Saturday of the month, because the ARRL Field Day event is next weekend.  When we got to breakfast at 8 AM there were already a lot of people there and seven more came in after us.  We did not take a head count but it was somewhere between 25 and 30 people.  We also did not have our usual waitress but the substitute very efficiently got everyone’s order taken and delivered.

The 40 foot tower on the east end of the house with the old OTA TV antenna on top.

The 40 foot tower on the east end of the house with the old OTA TV antenna on top.

I checked with Mike (W8XH) and he is available to help us get the antennas mounted on the small tower on Monday or Wednesday, assuming I have the cable entry box (CEB) installed and all of the necessary coaxial cable on hand.  Getting the CEB mounted was my main goal for today, but not the first thing I had to do.  I called Chuck as we were leaving breakfast at 9:15 AM.  He was at home and suggested we stop by there and pick up a key to his shop.  He was working on landscaping when we arrived so we did not stay long and we were back home by 10 AM.  Linda finalized her shopping list and headed off to gather the things she needed to prepare tomorrow’s brunch.  I changed into my work clothes, gathered up the laundry, put a load in the washer, and got to work on the CEB.

The CEB is designed to mount on the outside of the house, allowing wiring to pass between the inside and outside of the house in a way that is weather tight and animal proof.  Coaxial RF cables and control lines enter through the bottom, connect to lightning arrestors in the CEB that provide a path to ground if/when needed, and then continue through the wall of the house and thence to various devices.  Those devices might include cellular phone signal boosters, Wi-Fi systems, TV sets, satellite receivers, personal weather stations, or amateur radio gear such as radios, remote antenna switches, and antenna rotators.

The general area on the east end of the house at the base of he 40' tower where the CEB will be mounted.

The general area on the east end of the house at the base of he 40′ tower where the CEB will be mounted.

Superficially the installation looked simple.  With the copper back plane removed there were four mounting holes, one near each corner, and two large holes in the back.  All we had to do was hold the box against the wall, mark the locations of the four mounting holes and the big cable entry holes, set the box aside, drill the holes, put the box back up and secure it.  Right.  Sort of, but not exactly.  Mounting the box took seven hours to complete.

The first step was to remove the copper back plane with the three lightning arrestors installed on it.  I took care of that yesterday.  The next issue was that the house has shiplap siding, i.e., the east wall where I needed to mount the CEB was not a flat surface.  I decided to use 1″ square aluminum tube, installed vertically along the back of the box at the outside edges, to span multiple siding boards, ensuring that the CEB would be plumb.  I also decided to leave the tube long enough to go all the way to the ground and use it to support some the weight, in effect creating legs for the CEB.  That was Linda’s idea.  She’s a smart girl and a licensed amateur radio operator.

The back of the CEB with one of the vertical mounting bars.

The back of the CEB with one of the vertical mounting bars.

We had some surplus pavers and garden blocks and I found one that was just wide enough to catch the bottom of the legs.  I also had some left over paver base material, which meant I did not need to make a trip to the store.  The paver base material was from a project long, long ago (in a place far, far away) and I used it to create a base for the foundation paver, which was approximately 18″ x 12″.  I leveled the base side-to-side and pitched it away from the house for drainage.

Yesterday I purchased a 3′ long aluminum tube at Lowe’s and a 4′ long tube at The Home Depot.  Three feet turned out to be a good length, so I cut a foot off of the 4′ tube.  Things then got trickier.  The positioning of the CEB was critical as the two large holes in the back were for adapters for 2″ plastic conduit.  I was going to have to cut 3″ diameter holes through the bond that would come out above the plate on top of the concrete block foundation.  In the chosen mounting location the bottom corner holes in the CEB would be below the siding.  The lower right leg would be at least an inch away from the concrete block foundation and the lower left hole would be in front of a basement window opening so neither of these were going to be screwed into anything.

The CEB in position on the east end of the house with the door open. The copper backplane has been removed.

The CEB in position on the east end of the house with the door open. The copper backplane has been removed.

I wanted the CEB anchored at more than two points so I decided to drill two additional holes in the back, one on each side, approximately half way between the existing top and bottom holes.  I measured the spacing between the top and bottom holes as carefully as I could.  I measured down from the top end of each leg a distance for the top holes that was just sufficient to make sure the door of the CEB was below the 2″ iron gas pipe that runs horizontally along the outside of the house.  I measured down from there for the new middle hole and the bottom hole.  I then drilled the three holes through each leg by drilling opposing sides.  I had to use a powered hand drill for this work as my drill press was stored behind a large pile of RV furniture that we took out of the bus and was inaccessible.

I attached one of the legs to the back of the box using two short bolts through the top and bottom holes.  I then used the middle hole in the leg as a guide and drilled through the back of the CEB.  I repeated this procedure for the other leg.  I drilled the holes in the legs as accurately as I could but they did not quite line up so I had to enlarge them slightly by using the drill bit like a router bit.  Not ideal, to be sure, but aluminum is relatively soft and it worked.

The east end of the house with two 2" holes for the conduit.

The east end of the house with two 2″ holes for the conduit.

I attached each leg to the back of the CEB using 1.5″ 1/4-20 bolts through the bottom corner holes.  I snugged these up but left them loose enough that we could move the legs.  The top and middle holes were located in positions that would allow lag screws to be screwed into the siding and underlying plywood.  We had to tilt the legs to get them under the 2″ iron gas pipe and then straighten them and set them on the foundation paver.  We had to do this multiple times but it was easy once we figured out how to do it the first time.

With the CEB in position I marked the location of the holes for four 3″ 1/4-20 lag screws.  We removed the CEB so I could drill the holes for the lag screws and then put it back in position and screwed it to the wall.  I marked the locations of the two holes for the conduit as best I could and then unscrewed the box and removed it again.  I used our 1/2″ Craftsmen corded drill for the 3″ hole saw.  I bought this drill in 1978, along with a lot of other Craftsmen tools, when we moved into our house in Farmington Hills.  I still have almost all of those tools and they all still work.

The CEB in position with both pieces of conduit through the back.

The CEB in position with both pieces of conduit through the back.

With the conduit holes drilled I cut one of the 18″ lengths of conduit in half, inserted the pieces into the adapters, and placed them in the holes.  We then put the CEB into position, got the adapters through the holes in the back of the CED, and tried to line up the holes in the legs.  The conduit was being forced up as it went through the bond, especially the one on the left, and would not allow the holes in the CEB to line up with the holes in the legs.  We took the retaining rings off of the adapters and removed the CEB, again.

I shortened the conduit pieces to approximately 5″ and checked the fit in the holes.  We wrapped two bands of adhesive backed foam weather-stripping around each piece of conduit and placed them back in the holes.  I then applied a bead of adhesive caulk all the way around each adapter at the wall.  We put the CEB in position for the final time, got the conduit adapters through the holes, snugged up the retaining rings, and put the four lag screws in.  After tightening the four lag screws I tightened the two bolts in the lower corners.  I then tightened the adapter retain rings and put the open end caps on.  The conduit ended up getting pulled back out of the wall a bit so I used the thin end of a 10″‘wood shim to try and force the caulk back into the gap around the conduit adapter.  It did not go back in very well so I will have to figure out something else to seal around the conduit.

The CEB was finally installed and very solidly anchored.  I got the copper base plate and remounted it to the five studs (four corners and one center) using some antioxidant/anti-seize compound on the stud threads.  The last step (for today) was to install the snap in covers for the 16 cable entrance holes in the bottom of CEB.  I also ordered 16 grommets and will remove the caps and replace them with grommets as I install devices and run their cables and wires into the CEB.

The CEB with the copper backplane installed and the three Morgan lightning arrestors mounted (two lower left, one top center).

The CEB with the copper backplane installed and the three Morgan lightning arrestors mounted (two lower left, one top center).

The two pieces of conduit open into the sump pump room (large closet) in the northeast corner of the basement just above the wood plate that sits on top of the concrete block foundation.  I plan to install the SureCall Fusion5s 5-band cellular booster (amplifier) in this room to keep it close to the CEB and because there is AC power available there.  I bought an installation kit for the Fusion5s that includes a lightning arrestor which will get mounted in the CEB.  I also bought an amplifier for the OTA TV antenna that will mount on the tower a few feet below the antenna.  The amplifier will get its power through the coax from a power inserter that doubles as a lightning arrestor and will be installed in the CEB with the AC power supply (wall wart) in the sump pump room.

I did not get these two additional lightning arrestors installed today.  By the time we got the CEB installed we were tired.  The high temperature was OK (near 80?) but the relative humidity was very high.  I was also very sore the whole time, especially my left knee, undoubtedly the lingering after effect of using the power chisel earlier in the week to remove thinset and mastic from the floor of the bus.  Getting down and up at least 50 times during the afternoon did not improve matters, but we got it done.

Even though she was also tired, once we reached a point where I could finish up alone Linda got busy making several food items for tomorrow.  In the midst of all that she heated some Amy’s Lentil Soup and made grilled cheese sandwiches with Diaya cheese or dinner.  Diaya makes an excellent non-dairy cheese that works well cold or cooked into dishes.

After dinner I returned a call from Butch to find out more about their new property and buildings, and discuss bus and ham radio projects.  One of the things Linda made was an apple pie so we stayed up until it was cool enough to wrap up.  That turned out to be 10 PM, by which time we ready to turn in for the night.