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How to Make PVC Insulators

For those regularly using ham radio rigs, finding inexpensive DIY alternatives to more costly retail solutions is a worthwhile endeavor. One example is the use of common PVC pipe to create insulators for the antenna array. PVC is electrically inert, making it a natural choice for insulating and separating the leads from the transmitter to the antenna array.

Things You'll Need

1/2-inch diameter PVC pipe
Table saw
Drill
1/2-inch drill bit
File
Plastic cling wrap
Epoxy
Caulk gun

Instructions

- 1
  Cut the PVC pipe to the required length, using the table saw.
- 2
  Cut a notch one-third of the way into the sides of the PVC pipe. Space the notches evenly, alternating sides. These provide grip to the epoxy you will apply later on.
- 3
  Wrap the pipe tightly in plastic wrap. Fill the PVC pipe with the epoxy and caulk gun. The epoxy weighs down the insulator, reducing or preventing line sway.
- 4
  Wait for the epoxy to dry, based on the manufacturer's recommendations. Slowly peel off the plastic wrap.
- 5
  Drill a 1/2-inch hole near the top and bottom of the pipe. Bevel the insides of the holes, removing sharp edges inside the holes. Beveling is required to prevent undue abrasion and/or cutting of guide wires used with the array.

Ham Radio