Connectors for 3/4" & 1/2"Aluminum hard line.

Image Copyright Roger Halstead 2003


This Idea came from Bill (N8FUZ) and this particular pair of connectors were made by Bill.

The construction of the connectors is quite simple.

You start with a standard 3/4" compression coupling and it is cut in half as shown to the right. I don't have a complete compression coupling, or one cut in half, on hand, but you should get the idea.

Standard  BRASS, "barrel connectors" (Female to Female) are used to create a female UHF connector. This allows connecting a standard PL259 directly.

Clean the threads off one end of the barrel connector.  Starting at the end of the compression fitting where it was cut in half, drill a hole that is a tight fit for the barrel connector.  Even a press fit, or interference fit is fine. Insert the barrel connector until the face of the end with the threads removed is flush with the inside of the compression fitting as shown at left.

The joint between the compression fitting and the barrel connector is then soldered..

To prepare the 3/4" hard line, carefully cut the shield back far enough so that when the dielectric is removed the center connector will go into the barrel connector about 3/8" to 1/2" when the shield is inserted all the way into the compression end of the fitting..  In other words, make it a good fit.  The center connector is not soldered. 

A little "Pentrox", or dielectric grease on the shield where it contacts the brass might be a good idea


For 1/2" hard line the connector is much simpler.  Here is one cut off the end of a 1/2" run that still looks like new. (It wasn't on the outdoor end)

The adapter is nothing more than a double female compression fitting for 1/2" tubing.

The aluminum jacket is stripped back far enough so it bottoms out against the shoulder near the center of the connector.  The foam may be left long enough to extend into the PL259. If it is then the center of the connector may need to be reamed out a bit until the foam insulation slides through. The center conductor is let long enough to extent through and out of the center pin of the PL259. The back of the PL259 will be slightly loose before the connector is tightened.

The PL259 has been removed, pulling a bit of the center conductor out of the hard line to give a better look at the interior.

Although the adapter is water proof the PL259 renders that a moot point as it is not. Just weatherproof the adapter and connector the same as any other PL259 used outside in the weather.

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