Using Andrew FSJ1-50A 1/4" Superflex Heliax with PL-259 Connectors 8/16/2004
(click the small pictures to see a large picture in a new browser window)
This project evolved in an effort to make new jumpers for an old Phelps Dodge 2 meter duplexer. All of the jumpers, six of them, were each 8-3/4" long. This is a 9" length of FSJ1-50A 1/4" Superflex Heliax with one connector installed. Following are the details of how the connector is installed on the PL-259.
Use silver plated PL-259 connectors for ease of soldering. 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.
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.
I used a sharp Leatherman blade to score the jacket around and then a tapered cut all the way to the end so the jacket could be peeled off.
Be sure to put the outer shell of the PL-259 on the cable to avoid forgetting it later.
Use pliers to mash the end of the cable back 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.
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.
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.
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 on a damp sponge.
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.
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.
Screw the outer shell onto the connector body. Measure your jumper to insure you have the correct length. You're done.
Entire content of this page copyright by U.W. Tony King, W4ZT - 2004