Cover for the Lightning Arrester Block for an Antenna

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My friend Ray installed a dual frequency antenna for his ham radio. One was 2 meter (135 to 148 MHz) the other was 70 cm (420 to 450MHz). In the picture you can see a red box.1. Dual frequency antenna

The following picture is a blow up of the area of the first picture in the red box.  In this picture you can see the grounding block for the lightning arrestor for the antenna.2. Close up of grounding block for lighting arrester

Ray provided me a STEP model of a folded sheet metal cover that he designed to protect the junction from weather. The cover will screw to the back plate shown in the previous picture.3. SolidWorks folded sheet metal model

I imported the STEP file into SolidWorks and collected the bends so that I could make it into a sheet metal part that could be flattened4. SolidWorks flattened sheet metal model

I used some Loctite repositionable adhesive to glue a print of the flat pattern to a .090’ thick piece of Aluminum.5. Loctite repositionable adhesive

Smith Oxyacetylene TorchMiller Dynasty 200DXLincoln SP-250 MIG WelderClausing/Coldchester 15" Lathe16" DuAll Saw15" Drill Press7" x 9" Swivel Head Horizontal Band Saw20 Ton Arbor Press BridgeportLincoln LE  31 MP & Lincoln 210 MP
Reply:6. Flat pattern print glued to Aluminum plate

7. Center drilling holes

8. Hole sawing holes

9. Drilling holes

10. Band sawing plate

Smith Oxyacetylene TorchMiller Dynasty 200DXLincoln SP-250 MIG WelderClausing/Coldchester 15" Lathe16" DuAll Saw15" Drill Press7" x 9" Swivel Head Horizontal Band Saw20 Ton Arbor Press BridgeportLincoln LE  31 MP & Lincoln 210 MP
Reply:11. Belt sanding edges

12. Bending sheet metal

13. Bending sheet metal 2

14. Welding up edge

15. Edge Ground and polished

Smith Oxyacetylene TorchMiller Dynasty 200DXLincoln SP-250 MIG WelderClausing/Coldchester 15" Lathe16" DuAll Saw15" Drill Press7" x 9" Swivel Head Horizontal Band Saw20 Ton Arbor Press BridgeportLincoln LE  31 MP & Lincoln 210 MP
Reply:Cover all done and ready for shipping to Ray.16. In mounting position

-DonSmith Oxyacetylene TorchMiller Dynasty 200DXLincoln SP-250 MIG WelderClausing/Coldchester 15" Lathe16" DuAll Saw15" Drill Press7" x 9" Swivel Head Horizontal Band Saw20 Ton Arbor Press BridgeportLincoln LE  31 MP & Lincoln 210 MP