SteppIR Dream Beam 42 User manual
2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.CO TEL: (425)-453-1910 FAX: (425)-462-4415
Dream Beam 42
Assembly Manual
Craig Thompson 9CT DB42 Stack
2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.CO TEL: (425)-453-1910 FAX: (425)-462-4415
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2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.CO TEL: (425)-453-1910 FAX: (425)-462-4415
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2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.CO TEL: (425)-453-1910 FAX: (425)-462-4415
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DB42 Parts Pick List
NOTE: On some of the items in this pick list, we have given you more quantities than you need in
case for some reason you lose or damage some of the fasteners, and to protect against us shorting
you accidentally. There are two quantities listed - “included”, and “required”. As long as you have
the amount that is required, you are in good shape, but do not be alarmed if on some items you have
more than you need.
1
2
2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.CO TEL: (425)-453-1910 FAX: (425)-462-4415
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DB42 Parts Pick List (continued)
3
2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.CO TEL: (425)-453-1910 FAX: (425)-462-4415
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DB42 Parts Pick List (continued)
4
2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.CO TEL: (425)-453-1910 FAX: (425)-462-4415
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DB42 Parts Pick List (continued)
5
2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.CO TEL: (425)-453-1910 FAX: (425)-462-4415
Notes:
A large, cleared flat area is recommended for assembly of an antenna of this size and complexity.
Typically, an area 40 ft x 50 ft would be ideal. We recommend using sawhorses or sturdy tables
when installing the boom. By having the boom elevated, it is easier to ensure that the elements are
level. Rubber or nitrile gloves are recommended when applying the anti-seize to the stainless steel
fasteners or the aluminum boom sections.
If you do not have room near the tower to assemble the antenna, we suggest you find a place that
you can put the antenna together in it’s entirety and then disassamble as needed for transportation
to the tower area.
Use of a level for adjusting the Element Housing Units (EHU’s) is highly recommended. This is a
surprisingly accurate and consistent method. Simply place the level on the mast plate, and adjust
each element accordingly.
Be sure to use the anti-seize compound supplied to prevent the galling of the stainless steel fasten-
ers. There is one exception to this - do NOT use the anti-seize compound when connecting the
plastic sweeps coupler to the pole ends. This will be covered in more detail later in the manual.
STARTING ASSE BLY OF THE DB42 ONSTIR PRO YAGI
6
2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.CO TEL: (425)-453-1910 FAX: (425)-462-4415
NOTES:
Our boom pieces are all drilled on a very precise drill press. This ensures that all the bolts are
snug when assembled. If your boom ever gets damaged or destroyed we can now send the specific
replacement boom required. Always apply lubricant to stainless steel bolts that are using
stainless steel nuts. This will prevent the two from galling together. Each bolt has a specific
length for the tubing it is holding together this is critical so that only the shank is engaged in the tub-
ing. Use 5 washers per bolt to secure the bolt as shown in figure 1.2.
Apply a thin film of connector protector or a spray-on lubricant (i.e. Anti-seize, Noalox) to the
male engagement area of the boom sections.
The boom ends will have a color coding so that you know which pieces slide into each other.
Match the colors as shown in figure 1.1 below and slide the boom pieces together until the
pre-drilled holes align.
Secure the correct bolts and washers onto the boom as shown in figure 1.2
Repeat this for each section until the boom is completely assembled.
The final step is to secure the eyebolt as shown in figure 1.1 and figure 1.2
See washer placment in figure 1.2 for 1/4” and 5/16” boom bolts
1/4” X 3” Hex Bolt
60-0029 and five
1/4” flat washer
60-0041
1/4” X 31/4” Hex Bolt
60-0063 and five 1/4”
flat washer 60-0041 1/4” X 3 1/2” Hex Bolt 60-0100, five
1/4” flat washer 60-0041, Boom sleve
10-1203-21
1/4” X 3 1/4” Hex Bolt
60-0063 and five 1/4” flat
washers 60-0041
1/4” X 3” Hex Bolt
60-0029 and five 1/4”
flat washer 60-0041
1 3/4” Boom
Section
10-1202-01
2” Boom
Section
10-1202-11
2 1/4” Boom
Section
10-1202-21
2 1/2”
Boom
Section
10-1202-71
1 3/4” Boom
Section
10-1202-01
2” Boom
Section
10-1202-11
2 1/4” Boom
Section
10-1202-21
7/16” Eye bolt
Black
BlackRedRedBlue BlueRedBlack Red
Black
512”
Figure 1.1
No Color
No Color
Boom Assembly
3” Boom
Section
10-1202-81
2 1/2”
Boom
Section
10-1202-71
5/16” X 4” Hex Bolt 60-
0066 plus two 5/16” flat
washers 60-0033
Locate boom pieces in the Antenna Boom Box
QTY 2 1 3/4” X 72”
QTY 2 2” X 72”
QTY 2 2 1/4” X 48”
QTY 2 2 1/2” X 44”
QTY 1 3” X 72”
BOO ASSE BLY
7
2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.CO TEL: (425)-453-1910 FAX: (425)-462-4415
NOTES: When securing the eye-bolt and boom bolts to the boom, install the eye and the head of
the bolts on the same side of the boom, so that they will be facing upwards when the boom is
secured to the tower. The 1/4” boom bolts require 5 washers, as shown below in figure 1.2. The
5/16” boom bolts only require 2 washers, placed above the Nylock nut.
ELE ENT HOUSING UNIT INSTALL
Locate the four Element Housing Units (EHU) with gaskets, in the Antenna Box
QTY 1 Director 1 EHU 30m/40m Driven (This is the only EHU that has a plastic lid)
QTY 2 Director 3 and Reflector EHU 30m/40m Passive (both are identical)
QTY 1 Driven EHU 20m/ (with relay default to passive)
QTY 1 Driven EHU 20m/ (with relay default to Driven)
Locate the following parts for assembling the EHU’s
QTY 2 Return Element Support Tube (EST)
QTY 3 10-1608-01 Element Return Plate Small
QTY 3 Element mounting plate
Figure 1.2: Boom / Eye-Bolt Assembly
Bolt heads all facing up
Boom Bolt Assembly Eye-Bolt Assembly
QTY 3: 60-0041
SS Flat washers
QTY 2: 60-0041
SS Flat washers
No washers
needed for eyebolt
QTY: 1 60-0050
3/8” SS Nylock
QTY:1: 60-0030
1/4” Nylock Nut
See page 2 for spe-
cific bolt lengths QTY 1: 60-0151
3/8” x 4.5” SS Eye-bolt
BOO ASSE BLY (continued)
8
2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.CO TEL: (425)-453-1910 FAX: (425)-462-4415
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DB42 BOO ARKING TABLE
EZ Eye
Start Here
Figure 1.3
NOTES: We recommend that you use an aluminum saddle half for drawing your marks on the boom. Determine your
mark using figure 1.3 below, then draw a line on each side of the saddle piece. This prevents any possible mistakes on
where the saddle edge should be on the measurement. The truss anchor point between the boom bolts shown below is
the same on both ends of the boom. The EZ-Eye is NOT at the center point of the boom. Because of this, you will have
a short side and a long side in relation to the EZ-Eye. Position boom as shown below when measuring for your marks.
NOTES:
Figure 1.4 shows the measurements from centerpoint to centerpoint for each element. While we
have had you use the marking table measurements in figure 1.3 for placement of each item on the
boom, this next step of measuring centerpoint-to-centerpoint is extremely important to insure you
have proper center-to-center spacing between each element. When in doubt, always default to
these dimensions as It is critical to have accurate center-to-center spacing for the antenna to
work properly.
9
2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.CO TEL: (425)-453-1910 FAX: (425)-462-4415
Figure 1.4
REFLECTOR DRIVEN DIRECTOR 1
40M driven
DIRECTOR 2
180 Driven
Antenna Element Placement
DIRECTOR 3
BOOM TRUSS
Boom truss attachment
Center-to Center Element Spacing
6m Opt. Dir 1
(place on 2” boom)
6m Opt. Dir 2
(place on 3” boom)
6m Opt. Dir 3
(place on 2” boom)
Boom truss
attachment
10
2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.CO TEL: (425)-453-1910 FAX: (425)-462-4415
Locate pieces for Driven element assembly
QTY 1 70-3409-01 40M Driven Element Housing with passive/driven relay
QTY 1 10-1605-02 Aluminum Element Support Plate 6 1/2” X 27”
QTY 1 10-1608-01 Element Return Plate
QTY 2 70-2029-01 Element Support Tube EST extension
QTY 1 70-2028-01 Return EST extension
QTY 1 70-2027-01 Return EST extension with 6” aluminum splice
Note: To get all the elements level use a level to set each element plate. Then tighten the saddle clamps, make sure to
alternately tightening the bolts on the saddle clamps to avoid moving the plate
Refer to the marks on the boom from figure 1.3 for correct placement of the driven element. Figure
1.5 shows the 49 foot Element Housing and Return EST assembly.
Mount the Element Support Plate and Return Plate to the boom, leave the bolts loose enough to allow
for leveling adjustments.
Level the plates to the boom, so that the eye portion of the EZ eye is on the top side of the boom.
Attach the EST extension tubes as shown in figure 1.6 once the plates are secured.
Place the stress relief tubes over the applicable EST extensions as shown in figure 1.6 and figure
1.7
Tighten boom saddle bolts to 20ft/lbs (27.09Nm)
Tighten the EST extension saddle bolts to 15 ft/lbs (20.34Nm)
Follow figure 1.5 and figure 1.7 for correct assembly of EST extensions. Place the Stress Relief
Tubes over the applicable EST extensions as shown in figure 1.7.
Figure 1.5
Driven Element Support Plate
10-1605
Return Mounting Plate
70-2028-01 Return EST Extension 66 3/8”
70-2029-01 Driven EST Extension 60 3/4” 70-2029-01 Driven EST Extension 60 3/4”
70-2027-01 Return EST Extension with 6” splice69 3/8”
AST PLATE
The tips of EST extensions should be the
same distance from the boom to allow for
the telescoping poles to be mounted cor-
rectly. This will affect the straightness of the
element.
.4” ring for attaching rubber
boot and telescoping pole.
Shown later in manual
.4” ring for attaching rubber
boot and telescoping pole.
Shown later in manual
The tips of EST extensions should be the
same distance from the boom to allow for
the telescoping poles to be mounted cor-
rectly. This will affect the straightness of the
element.
3” Boom Section
Director 1 EST Extension Assembly
DIRECTOR 1 (49 foot) ELE ENT ASSE BLY
11
2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.CO TEL: (425)-453-1910 FAX: (425)-462-4415
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The items below will be used when performing the steps on page 11, 12 and 13.
12
2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.CO TEL: (425)-453-1910 FAX: (425)-462-4415
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Director 1 AssemblyFigure 1.6
13
2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.CO TEL: (425)-453-1910 FAX: (425)-462-4415
QTY 2: 2” x 3”
Stress relief splice
10-1630-11
QTY 1: 2” x 12”
Stress relief splice
10-1630-21
QTY 2: 2” x 3”
Stress relief splice
10-1630-11
Note:
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Figure 1.7
14
2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.CO TEL: (425)-453-1910 FAX: (425)-462-4415
Figure 1.8
Figure 1.9
Remove foam/cardboard pad from inside
driven housing. This is critical!
Refer to Figure 1.8 for assembly of the director
1 element housing, gasket and cover.
When the six screws are secured to the driven
element housing it can now be installed to the
driven element plate.
Refer to Figure 1.9 for attaching director 1 to
the element plate.
QTY 4: 10-32 X 3/4” SS screw
60-0017
QTY 6: 10-32 Nylock nut
60-0019
QTY 1: Director 1
housing 70-3409-01
QTY 1: Director 1
gasket
QTY 1: Director 1
housing cover 40m
10-1022-21
QTY 4: 10-32 X 3/4” SS screw
with nylon locking strip
60-0101
QTY 4: #10 SS washers
60-0018
QTY 4: 1/4” aluminum spacer
10-1613-11
The best location to place the
level when leveling the Driven
Element Support Plate is along
the lip of the element plate
Director 1 EHU Preparation
ounting Director 1 Housing
NOTES:
With the 1/4” aluminum spacers (10-1613-11, fig
1.8) under the EHU, the plastic extension tubes
roughly align with the center of the
1-3/4” fiberglass tube. Once the element has
been mounted, check to ensure that both the ele-
ment plate and return plate are level. All ele-
ments can be adjusted by loosening the alu-
minum saddles and rotating each element
accordingly. We highly recommend using a level
for this.
QTY 2 :60-0017-10
10-32x3/4” SS
FLATHEAD
SCREWS
2.5” OD
3” OD
Plastic extension tube
15
2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.CO TEL: (425)-453-1910 FAX: (425)-462-4415
The items below will be used when performing the steps on page 14.
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16
2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.CO TEL: (425)-453-1910 FAX: (425)-462-4415
QTY 10: 60-0018
#10 SS washer
QTY 1: 70-3409-01
Driven element EHU
QTY 1: 10-1502-01
Element housing gasket
QTY 1: 70-2030-01
Element Mounting plate
QTY 4: 10-1601-22
2” Aluminum saddles
QTY 4: 60-0046
5/16 SS Nylock nut
QTY 10: 60-0019
10-32 SS Nylock nut
QTY 4: 60-0065
5/16” x 3-1/2” SS Hex Bolt
NOTES:
Make sure to align the element to
the boom correctly, which direc-
tion it is facing affects the polarity
of the antenna.
Use a level to ensure that the
mounting plates are level in retro-
spect with each other, before
attaching the EHU’s.
This bolt should be
directly over center
of boom.
FIGURE 1.10 DB 42 20 Driven Element
Reflector 2” OD Boom Section 10-1202-11
QTY 10: 60-0017
#10 x 3/4” SS screw
N TE: The driven element and director 2
look identical in appearance, but have a
different relay board inside. Check the
part number sticker inside the EHU and be
certain that it matches the part number
above.
17
2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.CO TEL: (425)-453-1910 FAX: (425)-462-4415
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The items below will be used when performing the steps on page 15.
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