The original flanged coupler has a solid core, so as it is adjusted, the flange rotates. This is fine if it is used with an axisymmetric flange-mounted horn or a dish or lens which can rotate relative to the transceiver board. Where an experimenter wishes to connect the flange to something which cannot rotate, or where adjustment of the polarisation is needed, a new approach is required.
I separated the flange and central waveguide from the threaded barrel, and reamed a hole through the barrel. That allowed the flange to float and rotate, but it needed a clamp. I decided that a split nut which would fit over a raised ring on the shaft might work OK.
Nice simple machining job to enclose a 1.3GHz RFCI drop-in isolator (three-port circulator with a dummy load on the third port) and act as a heatspreader in case of a load fault. I had bought six RFSL2347s direct from RFCI, but only needed three. They can handle 200W CW, 1kW peak and 100W CW dissipation.
I sold two and this one was spare. I ran up a CAD design in Fusion360 to get the dimensions right, but then made it on my manual Bridgeport mill.
I ran a quick test in Fusion360 to look at the stresses around holes in a 1 metre aluminium boom with a large hole in the top and a cross-hole, with one end of the boom fixed and 200N on the other end. Just testing the facility to see how it works.
I’ve been trying out some ideas for a feedhorn that uses the dielectric-horn POTY approach with a 22mm circular guide for 10GHz suspended in the mouth of a 9cm horn. Quick video of the idea shows some issues, like it only works with the coax feed to the 10GHz horn when it is cross-polarized. Needs a lot more thought, but I needed to do this sketch to get it clear in my head. The outer tube is almost transparent in this rendering. It is 180mm long and 68mm OD. The open end of the 22mm tube will have an HB9PZK dielectric lens and the 68mm tube will have a thin dielectric plastic disk with a hole to support the 22mm tube. Hopeless like this though because of the cross-polarisation issue. More thought needed.
I needed a spider to support long workpieces out of the back of the headstock spindle. I had a bit of EN8 round bar so I used that. Bored to 42mm to match the spindle ID, then counterbored to fit the spindle OD. I used a 1mm slitting saw to form a clamp and milled out pockets for a couple of M3 caphead bolts. Bored out a hole in the end of three M8 cap bolts and made brass inserts. Works a treat.
This project is being implemented by the Goole Radio and Electronics Society. The antenna uses the modified PA0RDT Mini-Whip design. The PCB and component kit was put together as a kit by the late Dave Powis G4HUP and now sold by the UK Radio Astronomy Association. The kit only includes the electronics. I decided to make a proper enclosure, couplers and fittings to make a decent mechanical solution.
I made up another batch of my variant of the VK3CV model choked Chaparral®-style feedhorns. Chokes are 7mm diameter, bore is 2mm, Body is 30.75 x 15mm, with an adjustable 4mm diameter coupling cavity. These are made from brass.
Grooves are 0.5mm wide by 0.75mm deep, made with a toolpost spindle at 14,000 rpm using a two-flute carbide end mill in the lathe at 8rpm
I was asked to make up some quick-detach coupling tubes to allow two 24GHz round flanges to be clamped together. I made a tube with a 22mm x 0.75mm thread outside and broached a keyway slot, then made a brass key to fit and fixed it with Loctite. So far I’ve only made up one of the clamp rings, I’m waiting for a real example to turn up so I can get the tolerances exactly right. All its fine so far though.
Following the design in http://www.g4dbn.uk/?p=1333 I made up a trial version in brass. Anti-cocking flange, adjustable barrel and the standard sized coupler for a VK3CV design Silicon Radar 122GHz board.