Portable Antenna Mast System |
Overview
This is a simple antenna mast project which is designed to be both portable and rugged. Most other portable antenna mast designs are based around common PVC pipe, which severely limits the overall antenna height and size (wind load) they can handle.
The antenna mast design shown here will be based around common 3/4-inch and 1/2-inch diameter galvanized plumbing pipe and connectors. Using three sections of 4-foot long, 3/4-inch diameter galvanized pipe for the main mast will result in a very solid, 12-foot high antenna mast. The 3/4-inch diameter pipe will be a little too small for most stock antenna mounting brackets, so you may have to drill new antenna mounting holes or build your own bracket mounting system. Using larger diameter pipe for the bottom mast section and then tapering off with smaller diameter sections will also let you increase the overall antenna height. Non-metallic guy lines should be added if you want to go any higher, or if the antenna has a large wind load. The antenna stands leg's can also be stabilized to the ground using standard tent stakes, should you need to deploy on a grass or dirt surface.
Construction Notes & Pictures

Antenna mast parts overview.
On the top-left are three, 4-foot long pieces of 3/4-inch diameter galvanized pipe, an optional top cap, and two 3/4-inch couplers, and a 3/4-inch threaded floor stand. These will be for the making the mast the antenna mounts to.
Off to the far-right are four, 1-foot long pieces of 1/2-inch diameter galvanized pipe. These will be used to make the mast's base legs.
In the middle are four each of 1/2-inch diameter nipples, 90° elbows, and threaded floor stands.
You also need some assorted 1/4-inch stainless steel hardware. Wing nuts will be handy for quick assembly, and using stainless steel hardware will prevent rusting.

One leg of the mast's stand.
Take one of the foot long pieces of 1/2-inch diameter pipe, a 90° elbow, a short nipple, and a 1/2-inch threaded floor stand and put them together as shown. You may wish to add some Teflon tape to the threads to help secure the connections.

After you've made the four legs for the mast stand, drill a 1/4-inch hole through one end of the 1/2-inch diameter pipe, as shown above. This is how the legs will attach to the 3/4-inch floor stand which supports the main mast itself. Secure the legs using the 1/4-inch hardware.

Temporarily attach the legs to the center floor stand to check everything out. You can use whatever hardware is most convenient, but wing nuts are handy for quick assembly and disassembly.

Overview of the finished antenna mast stand.
Double-check that each of the legs are level. Twist the legs slightly if they don't match up.

To store the mast sections during transport, drill holes through each of the 3/4-inch pipes near each end. Place a large 1/4-inch threaded bolt through them and secure with wing nuts.

Add an optional bungee cord handle to the center mast section to make the mast bundle easier to carry.

Completed portable antenna mast system.
You may wish to store the mast stand legs, couplers, securing hardware, antenna hardware, and a wrench in an old ammo box or duffle bag attached to the main mast sections.
You may also wish to add a small tool kit in case you need to add or fix any RF connectors or cables.
The antenna's coaxial cable should be secured to the mast sections with zip ties or reusable velcro straps.
You may also wish to mark the mast sections with some tape to help with mast section identification during disassembly and transportation.

Another 3/4-inch floor stand can be attached to the top mast piece to make a platform for a magnetic mount antenna.

Completed antenna stand in operation.

Looking up the mast.
Antennas with a large wind load should only use two sections of pipe (8-foot overall height) unless you add some mast support guy lines.
Zinc-chromate paint was sprayed around any holes in the pipe to prevent rusting.