Category: DX Commander

I may be too late…

Important engineering upgrades in the antenna field – improving the foundations for the new lightweight tower, installing a Dead-Man anchor for the electric winch, and grounding the tower to the radial network.

The day starts with a look at the original winch post and the maths behind its load capacity. Although the first anchor could handle around 200 kg, the mechanical advantage of the increased height on the falling-derrick (not a “gin pole”!) introduced additional torque and stress. The solution? An engineered Dead-Man anchor buried crosswise – the same principle used in bridge and harbour design.

We pour, cure, and backfill the new anchor, review older ones, and make key decisions about reinforcement and concrete volume. Then it’s on to grounding: bonding the radial field directly to the tower base and cabinet using copper strap and self-amalgamating tape for long-term corrosion resistance.

Along the way, we cover:

➡️ Calculating load and fulcrum points on a small tower system
➡️ Practical tips for mixing and pouring small-batch concrete outdoors
➡️ Grounding and bonding strategy for multi-antenna installations
➡️ Managing radials around automated mowers
➡️ Handling real-world compromises when parts or materials are missing

Also featuring: spontaneous design decisions, visits from Junior and Django, drill bit snapping mid-hole!

By the end of the day, all anchors are upgraded, the tower base is bonded, and we’re ready for the next phase – raising the lightweight tower in time for CQ Worldwide.

0:00 – Intro & plan of attack
0:45 – Why the old anchor wasn’t enough
2:00 – Mixing and pouring the new concrete
6:00 – Upgrading existing anchors (and some decisions!)
8:00 – Explaining the Dead-Man concept
10:00 – Improvised engineering & “Callum moments”
13:30 – Dogs arrive on site
16:00 – Drilling, bending & building the Dead-Man anchor
20:00 – Grounding the tower and radials
23:00 – Review & next-phase tower talk

📡 More DX Commander builds:
➡️ [Signature 12.4 Setup and Test]
➡️ [40 m 4-Square Explained]
➡️ [Remote Station Build Series]

Caught in 60 mph gusts at Holly Farm. Watch the DX Commander Signature 9s, Rapides, and a Signature 18 bend, whip and hold firm through the storm. Nothing failed — just real-world proof these antennas can take it.

Remember the shock-cord "trick" I added to the Signature 18? Here it is: https://youtu.be/sIRSW5qJwD8

Testing 4-Square on 40m, the new 80m and 160m antennas too.

Today we’re commissioning the COMTEK / DX Engineering 40m 4-Square Antenna system here at DX Commander HQ. This is one of the most powerful setups for the 40m band — insane signal strength and front-to-back ratio. In this video I’ll take you through the build, wiring, tuning, fault-finding, and finally the moment of truth… including working Japan at +20dB over S9!

If you’re interested in serious DXing or contesting on 40m, the 4-Square is a game-changer.

Thanks to:

Tim Duffy K3LR and the DX Engineering team for the Comtek
Stefano at Messi & Paoloni for the 75 ohm coax
Martin and Mike for radial work and installation help

👉 Subscribe for more antenna builds, on-air tests, and DX Commander behind-the-scenes!

0:00 – Introduction & overview
0:20 – What is a 4-Square?
1:00 – Direction switching explained
1:45 – The COMTEK / DX Engineering controller box
3:00 – Wiring up & dummy load
4:45 – Software control with OM module
6:30 – Clickity-click relay tests
9:20 – Thank you DX Engineering
10:30 – Dummy load install
12:00 – Coax routing challenges
14:00 – Phasing line connections
16:30 – Trimming & tuning elements
19:00 – Resonance checks & adjustments
23:00 – Chat with Tim Duffy K3LR
24:30 – First tests & fault-finding
27:30 – T-piece troubleshooting
30:00 – Fixing a duff PL259
32:20 – Retesting antenna
33:15 – LIVE QSO with Japan (+20dB over S9!)
35:10 – Final thoughts: cost, complexity, and performance

#dxengineering
#dxcommander

Logging with my Captain’s Log Net Control Software – should be a fun demo – assuming it works!

See https://youtu.be/PV5GdAZ1nfo

This is my biggest antenna build yet! A full 160m / 80m fan dipole — from scratch, all the way through to WSPR testing.

In this video you’ll see:
✅ Preparing and painting the poles
✅ Building the dipole centre and elements
✅ Coax, balun and choke setup
✅ Raising the mast (the epic lift 🙂
✅ Tuning and first SWR tests

It’s rare to see a compact 160m solution paired with a full-sized 80m dipole, so I wanted to document the entire process in detail.

If you’re into low-band antennas, DIY builds, or just enjoy big projects coming to life, you’ll love this one.

📡 Subscribe for more antenna builds, ham radio experiments, and contest action.

💬 Drop a comment if you’ve ever tried 160m — I’d love to hear what worked (or didn’t!) for you.

0:00 – Teaser – The big lift (hook)
0:12 – Preparing the Poles – Painting, fitting, grinding, ramming sections together
6:31 – Planning the Dipole – Measurements, wire lengths, horseshoe layout
9:38 – Cutting & Prepping Wire – Kevlar cord, foldbacks, dipole centre
15:33 – Coax & Balun Setup – Patch leads, choke discussion, memories of Barry
21:00 – Coax Assembly – Measuring, cutting, connectors, testing continuity
31:20 – Adding 80m Legs – Fan dipole build begins
34:00 – Matching & Impedance Talk – 75Ω quarter-wave match explanation
36:05 – Mounting & Bolting Mast – Drilling, washers, test-fit
42:50 – Securing Mast – Bolts, levelling, wide shot
48:40 – Next Day Setup – Tensioning, knots, wind test
51:00 – 160m & 80m Alignment – Galvanised fixings, lifting elements
56:13 – 80m Wire Install – Cleats, pilot holes, tensioning
1:00:00 – Coax & Final Tension – Routing, connectors, self-amalg tape
1:03:30 – Testing & SWR – Adjustments, bandwidth discussion
1:05:30 – Wrap Up – Sign-off and next project
1:06:27 – Easter Egg – Intentional error / correction

Logging with my Captain’s Log Net Control Software – should be a fun demo – assuming it works!

Today’s job: holes, concrete, steel, and planning for two towers!

I unpack a new 12V winch, sort out the scaffold-pole mount at 45°, and dig in proper foundations with concrete and a dead-man anchor. This winch will let me safely lower the big tower and salvage one of the alloy poles.

At the same time, I’m sketching out a second, lightweight tower project — two poles, simple guying, base rotator, and even a budget bearing solution using UHMW washers and split bearings. The aim is to show how you can build a low-cost demonstrator mast that anyone could replicate.

Along the way:

Unboxing and testing the winch (Kevlar rope + remote)

Digging, cutting, concreting, and anchoring

The “dead-man” anchor trick explained

Planning the mini-tower with simple bearings and rotator setup

Updates on the ACOM 2020S amplifier and station progress

This is a proper “hands-on” day in the field — concrete dust, angle-iron, scaffold poles, and all!

👉 Have you ever pushed up your own mini-mast on three guys? Drop your stories in the comments — I’d love to hear how you tackled it.

Enjoy your radio, see you next time. 73,
Callum, M0XXT

0:00 – Winch unboxing & first look
0:28 – Scaffold pole mount idea (45°)
1:26 – Plan to recover alloy pole & use CB/10m Yagi
2:44 – Positioning the winch & anchor point
3:21 – Call to steel stockholder (angle iron sorted)
4:00 – Thinking ahead: lightweight tower plan
6:10 – Measuring guy triangle layout
6:43 – Digging the first foundation hole
7:28 – Cutting scaffold pole & mixing concrete
8:50 – Setting the winch mount pole
10:25 – Concrete mix going in
11:00 – Load calculations & safety margin
12:00 – Dead-man anchor explanation
13:05 – Laying out tower two with guy points
14:20 – Side quest: lawn mower service (spider included!)
14:25 – ACOM 2020S update
16:22 – Using scaffold elbow for base hinge
17:14 – Cheap & cheerful mini-tower design philosophy
18:00 – Rotator bearing plan with UHMW washers
19:30 – Bargain split-shaft bearings (£9 for two)
20:06 – Second hole and concrete base for mini-mast
22:50 – Checking alignment & straightness
24:09 – Cabinet and battery mount thoughts
25:30 – Big tower plans (20m Yagi coming soon)
26:30 – Spray painting poles (yellow → black & white)
27:26 – Wrap up & call for viewer experiences