Using Andrew FSJ1-50A 1/4" Heliax with PL-259 Connectors

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Using Andrew FSJ1-50A 1/4" Superflex Heliax with PL-259 Connectors

http://w4zt.com http://w4zt.com/repeater/duplexer/superflex/

This project began as an effort to make new jumpers for an older Phelps Dodge duplexer. All six of the original jumpers were each 8-3/4" long (but don't take that as gospel, measure yours and use that measurement). Following are the details of how the PL-259 connector is installed on the Superflex. Each photo is a thumbnail and will enlarge to a full size photo. Click on the "Back" button of your browser to return here.

1 This photo shows a single 9" length of FSJ1-50A 1/4" Superflex Heliax with one connector installed. The following steps will install a matching connector on the other end.

2 Use Teflon silver plated PL-259 connectors for ease of soldering and because nickel plated connectors have been proven to cause problems at VHF and UHF. In this example, the jumper needed to be 8-3/4" long. I cut a piece of cable 9" long by simply cutting with a pair of lineman's pliers.

3 Prepare the end of the cable by measuring the distance from the end of the cable to the end of a UG-176/U which is normally used when installing a PL-259 on RG-59 sized cable.

4 I used a sharp Leatherman knife blade to score the jacket around and then a tapered cut all the way to the end so the jacket could be peeled off.

5 Be sure to put the outer shell of the PL-259 on the cable NOW to avoid forgetting it later.

6 Use pliers to mash the end of the cable back to round so you can push the UG-176/U over the end and against the jacket of the Superflex. With the UG-176/U in place, score the spiral groove of the superflex between the UG-176/U and the end of the cable with a sharp knife.

7 Use diagonal cutters to grab the end of the spiral and begin peeling it back around the dielectric until you reach the UG-176/U.

8 Cut the excess copper spiral off and flatten the end of the copper against the end of the UG-176/U. Cut the foam dielectric back from the end of the cable to within about 1/8" of the UG-176/U.

9 Using a hot soldering iron, solder the copper spiral to the end of the UG-176/U. Also place a few solder points around the end of the UG-176/U to provide an easy way to solder through the connector body to. Cool the UG-176/U with a damp sponge.

10 Screw the UG-176/U into the connector body and tighten with pliers. Solder the end of the UG-176/U to the connector body in one spot to prevent any possibility of it turning. Cut the 1/8" remaining center conductor off even with the end of the connector center pin.

11 Solder the center pin. Solder through two opposing holes in the connector body to insure a positive electrical connection between the UG-176/U and the connector body. Be careful in this step to get a good solder joint but not to overheat the connector. After each soldering operation, cool the connector against a damp sponge.

12 Screw the outer shell onto the connector body. Measure your jumper to insure you have the correct length.
You're done!

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Original article text and photos are © Copyright 2007 by Tony King W4ZT, All Rights Reserved
Mike WA6ILQ of Repeater-Builder edited some text, simplified the original HTML, and added a credit line to Tony.
Originally posted 01-Sept-2007.

This web page, this web site, the information presented in and on its pages and in these modifications and conversions is © Copyrighted 1995 and (date of last update) by Kevin Custer W3KKC and multiple originating authors. All Rights Reserved, including that of paper and web publication elsewhere.

This project began as an effort to make new jumpers for an older Phelps Dodge duplexer. All six of the original jumpers were each 8-3/4" long (but don't take that as gospel, measure yours and use that measurement). Following are the details of how the PL-259 connector is installed on the Superflex. Each photo is a thumbnail and will enlarge to a full size photo. Click on the "Back" button of your browser to return here.
1	This photo shows a single 9" length of FSJ1-50A 1/4" Superflex Heliax with one connector installed. The following steps will install a matching connector on the other end.
2	Use Teflon silver plated PL-259 connectors for ease of soldering and because nickel plated connectors have been proven to cause problems at VHF and UHF. In this example, the jumper needed to be 8-3/4" long. I cut a piece of cable 9" long by simply cutting with a pair of lineman's pliers.
3	Prepare the end of the cable by measuring the distance from the end of the cable to the end of a UG-176/U which is normally used when installing a PL-259 on RG-59 sized cable.
4	I used a sharp Leatherman knife blade to score the jacket around and then a tapered cut all the way to the end so the jacket could be peeled off.
5	Be sure to put the outer shell of the PL-259 on the cable NOW to avoid forgetting it later.
6	Use pliers to mash the end of the cable back to round so you can push the UG-176/U over the end and against the jacket of the Superflex. With the UG-176/U in place, score the spiral groove of the superflex between the UG-176/U and the end of the cable with a sharp knife.
7	Use diagonal cutters to grab the end of the spiral and begin peeling it back around the dielectric until you reach the UG-176/U.
8	Cut the excess copper spiral off and flatten the end of the copper against the end of the UG-176/U. Cut the foam dielectric back from the end of the cable to within about 1/8" of the UG-176/U.
9	Using a hot soldering iron, solder the copper spiral to the end of the UG-176/U. Also place a few solder points around the end of the UG-176/U to provide an easy way to solder through the connector body to. Cool the UG-176/U with a damp sponge.
10	Screw the UG-176/U into the connector body and tighten with pliers. Solder the end of the UG-176/U to the connector body in one spot to prevent any possibility of it turning. Cut the 1/8" remaining center conductor off even with the end of the connector center pin.
11	Solder the center pin. Solder through two opposing holes in the connector body to insure a positive electrical connection between the UG-176/U and the connector body. Be careful in this step to get a good solder joint but not to overheat the connector. After each soldering operation, cool the connector against a damp sponge.
12	Screw the outer shell onto the connector body. Measure your jumper to insure you have the correct length. You're done!