A helical filter need not be large or heavy. I wrote in SOTA News Dec 2011 -
An Anti-pager Filter for 2m Handys by Rod M0JLA
After several unsuccessful activations and some research on the SOTA blog I decided to make a filter. (There is a lot more to tell but sticking to the actual process will be more useful to others who come to the same conclusion.) This article is aimed more at hill-walkers picking up a radio for SOTA than Advanced Amateurs putting on new boots and waterproofs. The main aim here is to list the mistakes I made and suggest ways of avoiding them. With support and guidance from Colin, G8JSM, I have completed construction and some alignment and testing. Field use will have to wait for the next activation suffering from pager blight and I will report on the results later on.
Design was easy using the Helical program [1]. Specify centre frequency, width and impedances; assign values for the analysis graph and a couple of clicks give you a sketch with dimensions and a selection of performance charts. I tinkered with the filter impedance (the only freely alterable variable) and trial and error led me to the final design:- 2MHz bandwidth centred on 145.5MHz with four loose coils of stiff wire tapped for 50ohm feed in a four compartment box.
Mistake ONE. Wire is a bit too thin at 1.25mm; the coils vibrate rather freely. Use the thickest wire the spec permits (a range is offered) and redesign if much less than 2mm.
I worked out the size of pieces required allowing for 2mm thickness and made the box from DS copper clad board which I tried to cut with a slitting saw. It jammed repeatedly and I ended up using a hacksaw. The pieces were filed to size and good fit. If you are good with sheet metal I think a tinplate box would be better.
Mistake TWO. Don’t even think of making this using lead-free solder unless you are equipped with the right sort of iron (I am not convinced that there is such an item!) and you know exactly what you are doing. The joints on mine are a disgrace and I was getting nowhere fast in a half-completed box until a contact suggested old style solder. I bought a reel of 60/40 non-corrosive flux cored solder. What a difference!
It might be worth mentioning a mistake or two that I didn’t make. The lid needs attaching with screws, so nuts need soldering inside the box (3.5mm seem OK). Don’t be so neat and tidy that the lid will fit either way around; offset at least one nut (and the corresponding screw hole). Colin suggested adding tuning screws and I soldered nuts to the outside of the lid at the compartment centres and then drilled right through the nuts tapping size to allow me to drill the lid from the inside to clear the screws.
All being completed I was ready to test and align. Previous mistakes are minor blips compared with what went wrong next. I don’t have a sweep generator; nor do I have an oscilloscope that does much above 100MHz. At the time my signal generator was broken so I decided to tune using VSWR which the Helical program shows very clearly as a mirror of the passband. Using a 2m FM transceiver through a VSWR meter into the filter and terminating with a dummy load looked like a suitable arrangement. WARNING! This could damage your radio; Colin advises a 3dB attenuator in line here to protect the PA stage. VSWR was not very responsive; no dip. I broadened the tuning range, discovering in the process that the radio had been wide-banded, and found the dip at 164MHz.
Stop and think very hard if this happens. Don’t automatically assume that your filter is totally wrong. Check, of course, that you haven’t made a silly mistake and when you find that the filter is as specified think what else might be wrong.
Mistake THREE. There were three other items involved here but I chose to concentrate on the filter, stretching and twisting the coils beyond repair. Then I made a new set more tightly wound; similar result after an epic battle getting them into the box (it’s easy when the box only has one side; once the other two are soldered on there isn’t much room). Then I did it again with the originally specified diameter but more turns; little difference. At this point I gave up. (What was actually wrong? See below.)
I mentioned this fact on the blog in passing while commenting on someone else’s problems with being heard and not hearing the reply. Richard, G3CWI, immediately came back offering to align it for me if I sent it to him and Colin also came back with more help. By then Viki, M6BWA, had experienced another difficult activation (Wentwood) so I decided to have another go. I first followed Colin’s advice and trimmed the over-long coils to the correct number of turns plus an extra half turn. Then I stretched the coils out to the correct design length.
This time I set the radio to 145.5FM and locked the dial. With all the adjusting screws removed I followed his advice again and extended an Allen key through the screw hole over the first coil. A dip was observed, causing some excitement! Unfortunately the adjusting screw was too short and so was the longest in stock, but not by much so I used it, getting a weak dip. Then I turned the filter end-for-end (which is why you need the lid fitting one way around only so the adjusting screws don’t get switched if you take the lid off) and repeated the process; bigger dip! The same again for the middle two coils and then a phenomenon I will come back to was observed. Clearly the screws being too short stopped further progress so I locked together two nuts on the end of the ineffective screws and tried again. This proved very successful and tuning was completed.
Or was it? I think that there was still a residual effect from the original problem. Certainly the local repeater,GB3ZA, suffered a seriously reduced signal (it did open this time) though nothing like as reduced as the local pager on 153.03 which was down at least 40dB on the S-meter.
Mistake FOUR. My dummy load may be OK at HF. It never occurred to me to test it but I now know that it has a resonance in the upper end of the VHF band, hence the original dip at 164MHz was actually the minimum VSWR of the dummy load. I think this effect skewed the readings even at 145.5MHz.
By this time my new (to me) and quite elaborate signal generator had arrived so I tried a different technique. My 2m analyser acts as a very sensitive tunable signal strength meter so I set the sig gen to a few microvolts at 145.500, tuned in the analyser and adjusted to fsd. Putting the filter in circuit caused a drop of several dB but a bit of careful screw turning gave me a fairly decent peak. The limited tuning range of the 2m analyser limits any attempt at producing a performance chart, so I went back to the radio for final testing. A quick retune at 145.500MHz and then tests over the range, showing 64dB down at 141MHz and 151MHz. GB3ZA opens and returns S9+60 and GB3VM returns S5 but I am told that it is not fully quiet with 10W as it used to be. With luck the filter might even reduce breakthrough when I am on 2m ssb and Viki is on 2m FM.
The peak is not tidy at all (see chart on Flickr), which brings me back to “A phenomenon I will come back to”. Three of the four coils tune fairly smoothly; the fourth behaves very oddly by comparison, with much faster meter movement and a hint of a double peak. This was easily noticeable using the VSWR method; less easy when relying on a bar graph S-meter.
Clearly, there remains some unfinished business apart, of course, from the field test. This is scheduled for the Clywdian Hills on 13th, 14th and 15th December. I think we are expecting difficulty on Cyrn-y-Brain
Rod, M0JLA with many thanks to G8JSM and G3CWI for their support.
[1] Helical program download from www.tonnesoftware.com
[2] Pictures of Colin’s (G8JSM) filter http://www.flickr.com/photos/g8jsm
[3] Pictures of my filter www.flickr.com/photos/m0jla
73
Rod M0JLA
PS the field test was conclusive on CyB.
The links appear to be out of use - sorry.