Post by Night Ranger on Jun 12, 2012 6:05:58 GMT -5
I have a Wilson 500 magnetic base mobile antenna. The coax leading to the antenna has developed a short about three feet from the base of the antenna. Is there any way to open up the base and solder good coax to the bottom without destroying the magnetic base part in the process?
Thanks,
Night Ranger
========================
...and a few minutes later....
I just found the following web page that appears to have the answer. The following web page list details on how open up and repair several of the Wilson antennas;
: )
Night Ranger
=======================================
From the web page at;
www.angelfire.com/tx/ChargersCastle/CBStuff/Coax.htm
Technical Support
Replacing Coax Cable
Replacing the coax cable on the various Wilson antennas is not a difficult task. The amount of time should be 10-20 minutes, depending on the model. As with any other bench work, careful attention to the soldering job will produce excellent results. Always double check each soldering step for a good flow of solder, a clean connection with no "cold" solder joints, and no loose strands of coaxial cable to short out. Described below are the proper steps for each of the different models.
A. Wilson 1000 & 5000 Roof or Trunk Lip
These are the simplest and easiest models to change or replace the coax.
1. Remove the loading coil from the mount.
2. If trunk-lip model, remove mount body from trunk-lip mount.
3. Using either a small screwdriver or a pair of pliers, carefully remove plastic cap covering center conductor.
4. Unsolder center conductor from pin.
5. Unsolder shield from clamp.
6. Coax cable will now be free from mount body.
7. Unsolder brass ring from shield.
8. This completes the removal of the old coax cable.
9. Using a new 18' length of RG/58 (or Mini 8) coax, trim the coax until the following is exposed:
Center conductor: 1/4" Foam covering: 1/2" Shield exposed: 1/4"
10. Slide brass ring (large end first) onto coax until small end is even with the outer rubber covering.
11. Prepare clamp slot by melting a light amount of solder onto the slot.
12. Fold shield back over the top of the brass ring.
13. Insert brass ring into clamp slot on mount body, and solder for complete connection. Solder should be enough to fill cavity of slot, yet not running out or sloppy. Be careful of the amount of heat and length of time iron is on ring, to prevent melting foam covering center conductor.
14. Check to verify that the solder joint is good and does not have a "cold" solder joint.
15. Tin 1/4" exposed center conductor with a light amount of solder.
16. Solder the center conductor to the center pin on the mount body.
17. Visually check to verify that no strands of shield or center conductor is shorting out, then use an ohm meter to verify.
18. Replace plastic cap, and re-assemble mount body onto trunk-lip or roof top mounting. NOTE: If using Mini 8 coax, the plastic cap cable slot must be enlarged to accommodate the larger diameter of this coax. This may be done by using a small "round file" to reshape the opening for the cable.
19. Install a new PL-259 on radio end of coax cable.
B. Wilson 1000 Magnetic Mount
Because of the tight tolerance of spacing, careful attention must be paid to the assembly and soldering of the center conductor.
Follow these steps carefully, and you will encounter no problems.
1. Remove the loading coil from the magnetic mount assembly.
2. Using a 3/4" open end or crescent wrench, Loosen and remove the hex nut, and lock washer, attached to SO-239 mount.
3. Pull plastic cover up and over top of SO-239, and lay cover over to expose internal magnet mount assembly.
4. Cut and remove cable tie wrap from coax.
5. Cut coax cable to free plastic cover from assembly.
6. Pull out and remove coax from cover assembly.
7. Un-solder center conductor from bottom of SO-239 mount.
8. Using a 9/16" rachet on the bolt at the bottom of the magnet, and a 9/16" open end wrench on the top, loosen and remove nut holding "U" bracket to magnetic plate.
9. Remove lock washer, lug and bracket from bolt.
10. Discard lug, and replace with a new unit.
11. Using a new 18' length of RG/58, push end of new coax into the coax hole on side of plastic cover, and pull 6 to 8 inches inside for an easy working length.
12. Trim this end of the coax until the following is exposed:
Center conductor: 1/4" Foam covering: 1 1/2" Shield exposed: 3/4"
13. Tin, with solder, the 1/4" exposed center conductor.
14. Tin, with solder, the 3/4" of exposed shield.
15. Insert bolt, with plate washer, through bottom of magnet plate hole.
16. Install SO-239 bracket on bolt extending through hole.
17. Install new lug onto bolt through SO-239 bracket.
18. Install internal tooth lock washer, then nut onto the bolt.
19. Re-tighten nut for secure fit.
20. Insert tinned center conductor into center pin hole of SO-239. Bend at a 90 angle, and fill hole with solder.
21. Insert tinned shield into the cleaned lug hole and solder.
22. Warning: clearance is very tight. Visually check to verify that no strands of shield or center conductor is shorting out, then use an ohm meter to verify. Also check for poor or "cold" solder joints.
23. Place cable tie on coax cable inside plastic cover, one inch from end of coax rubber covering. Tighten securely, as this will provide a strain relief for the coax cable to prevent cable from pulling out of mount. Trim off excess tie wrap.
24. Pull excess cable through hole until strain relief is against inside of plastic mount cover.
25. Slip cover over magnet housing, and press to fit tightly against completed assembly.
26. Install lock washer, nut, then tighten securely.
27. Install a new PL-259 on radio end of coax cable.
C. Wilson 500 Magnetic Mount
The Wilson 500 coil is not removable from the mount, therefore the replacement of coax cable is vastly different, but can be easily accomplished.
1. Turn antenna upside down so the bottom covering is facing you.
2. Cut an X configuration at the center, and carefully fold back the cuts, to expose the 9/16 hex bolt head. NOTE: A new vinyl pad is available from wilson if desired.
3. Using a 9/16" socket, loosen and remove the bolt.
4. This will cause the magnet plate to fall free from the antenna, and expose the underside of the antenna. Notice that the center conductor of the coax cable feeds into the coil and is not accessible.
5. Cut the old coax cable at a point between the cable tie wrap (strain relief) and the exit hole.
6. Pull old coax cable free and discard.
7. Cut cable tie wrap from remaining coax cable portion.
8. Remove outer rubber covering and shield from coax cable by sliding it off from the remaining coax. This will leave only the foam covered center conductor.
9. Cut this center conductor to a length of 1 1/2".
10. Trim the foam covering to expose 1/2" of center conductor.
11. Insert a new 18' length of RG/58 coax cable through hole in plastic cover, and pull 6 to 8" inside for an easy working length.
12. Trim this end of the coax until the following is exposed:
13. Center conductor: 1/2" Foam covering: 1/2" Shield exposed: 1/2"
14. Tin both exposed and trimmed center conductors.
15. Splice the center conductors together by inter-wrapping them together, then soldering the connection.
16. Starting 1/2" above soldered wire, wrap electrical tape around the foam conductor to a point 1/2" below
soldered wire.
17. Repeat to ensure a double covering of tape over the cable.
18. Solder a new lug onto the trimmed shield.
19. Place cable tie on coax cable inside plastic cover, one inch from end of coax rubber covering. Tighten securely, as this will provide a strain relief for the coax cable to prevent cable from pulling out of mount. Trim off excess tie wrap.
20. Pull excess cable through hole until strain relief is against inside of plastic mount cover.
21. Visually check to verify that no strands of shield or center conductor is shorting out.
22. Place lug's center hole over threaded hole of coil housing.
23. Carefully replace magnetic plate on bottom of antenna.
24. Screw 9/16" bolt through bottom of magnetic plate hole and into coil.
25. Securely tighten with 9/16 socket.
26. Fold down cut slots of vinyl trim, so that the bottom portion is stuck to the bolt.
27. Install a new PL-259 on radio end of coax cable.
D. Wilson Little Wil Magnetic Mount
1. Turn antenna upside down so the bottom covering is facing you.
2. Cut an X configuration at the center, and carefully fold back the cuts, to expose the 1/2" hex nut.
3. Using a 1/2" socket, loosen and remove the hex nut and lock washer.
4. Remove chrome mast from the top of the antenna.
5. Remove small rubber washer from threaded top bolt.
6. Carefully peel back the outer edges of the black vinyl pad covering the bottom, so that the magnetic plate is loose.
NOTE: A new vinyl pad cover is available for replacement use if desired.
7. Using a pair of needle nose pliers, forcefully pull keeper from base cover. (This is at the coax cable entry point, and located directly beneath the coax.) Pull coax loose from housing.
8. This will cause the antenna to disassemble into three separate pieces: the magnet plate, the coil, and the black plastic housing
9. At the bottom of the coil, remove shield lug on bolt.
10. Unsolder center conductor from coil wire.
11. Remove black electrical tape protecting capacitor.
12. Unsolder capacitor from the center conductor.
13. Cut capacitor loose at shield lug, and discard old coax.
14. Prepare a new 18' length of coax with the following exposed:
Center conductor: 1/4" Foam covering: 1" Shield exposed: 1/2"
15. Insert the exposed shield lead and one end of the capacitor into the eyelet of a new lug, and solder.
16. Solder both the exposed center conductor of the coax and the remaining end of the capacitor the coil wire.
17. Check to verify that the solder joints are good and do not have any "cold" solder joints.
18. Cover capacitor and exposed bare leads with electrical tape.
19. Slide shield lug back onto bottom coil bolt.
20. Place a cable tie on coax cable, one inch from end of coax rubber covering. Tighten securely, as this will provide a strain relief for the coax cable to prevent cable from pulling out of mount. Trim off excess tie wrap.
21. Re-insert antenna coil back into housing.
22. Install rubber washer and chrome mast on top, and tighten securely.
23. Install coax cable so that it is tight and inserted into channel.
24. Apply a small amount of glue to the sides of the plastic coax keeper, and re-insert fully into slot.
25. Carefully replace magnetic plate on bottom of antenna.
26. Place lock washer on extending bottom bolt, and screw 1/2" nut onto bolt extending through bottom of magnetic plate hole.
27. Securely tighten with 1/2" socket.
28. Fold down cut slots of vinyl trim, so that the bottom portion is stuck to the bolt. Reseal outer edges of vinyl pad to bottom of magnet.
29. Install a new PL-259 on radio end of coax cable.
Thanks,
Night Ranger
========================
...and a few minutes later....
I just found the following web page that appears to have the answer. The following web page list details on how open up and repair several of the Wilson antennas;
: )
Night Ranger
=======================================
From the web page at;
www.angelfire.com/tx/ChargersCastle/CBStuff/Coax.htm
Technical Support
Replacing Coax Cable
Replacing the coax cable on the various Wilson antennas is not a difficult task. The amount of time should be 10-20 minutes, depending on the model. As with any other bench work, careful attention to the soldering job will produce excellent results. Always double check each soldering step for a good flow of solder, a clean connection with no "cold" solder joints, and no loose strands of coaxial cable to short out. Described below are the proper steps for each of the different models.
A. Wilson 1000 & 5000 Roof or Trunk Lip
These are the simplest and easiest models to change or replace the coax.
1. Remove the loading coil from the mount.
2. If trunk-lip model, remove mount body from trunk-lip mount.
3. Using either a small screwdriver or a pair of pliers, carefully remove plastic cap covering center conductor.
4. Unsolder center conductor from pin.
5. Unsolder shield from clamp.
6. Coax cable will now be free from mount body.
7. Unsolder brass ring from shield.
8. This completes the removal of the old coax cable.
9. Using a new 18' length of RG/58 (or Mini 8) coax, trim the coax until the following is exposed:
Center conductor: 1/4" Foam covering: 1/2" Shield exposed: 1/4"
10. Slide brass ring (large end first) onto coax until small end is even with the outer rubber covering.
11. Prepare clamp slot by melting a light amount of solder onto the slot.
12. Fold shield back over the top of the brass ring.
13. Insert brass ring into clamp slot on mount body, and solder for complete connection. Solder should be enough to fill cavity of slot, yet not running out or sloppy. Be careful of the amount of heat and length of time iron is on ring, to prevent melting foam covering center conductor.
14. Check to verify that the solder joint is good and does not have a "cold" solder joint.
15. Tin 1/4" exposed center conductor with a light amount of solder.
16. Solder the center conductor to the center pin on the mount body.
17. Visually check to verify that no strands of shield or center conductor is shorting out, then use an ohm meter to verify.
18. Replace plastic cap, and re-assemble mount body onto trunk-lip or roof top mounting. NOTE: If using Mini 8 coax, the plastic cap cable slot must be enlarged to accommodate the larger diameter of this coax. This may be done by using a small "round file" to reshape the opening for the cable.
19. Install a new PL-259 on radio end of coax cable.
B. Wilson 1000 Magnetic Mount
Because of the tight tolerance of spacing, careful attention must be paid to the assembly and soldering of the center conductor.
Follow these steps carefully, and you will encounter no problems.
1. Remove the loading coil from the magnetic mount assembly.
2. Using a 3/4" open end or crescent wrench, Loosen and remove the hex nut, and lock washer, attached to SO-239 mount.
3. Pull plastic cover up and over top of SO-239, and lay cover over to expose internal magnet mount assembly.
4. Cut and remove cable tie wrap from coax.
5. Cut coax cable to free plastic cover from assembly.
6. Pull out and remove coax from cover assembly.
7. Un-solder center conductor from bottom of SO-239 mount.
8. Using a 9/16" rachet on the bolt at the bottom of the magnet, and a 9/16" open end wrench on the top, loosen and remove nut holding "U" bracket to magnetic plate.
9. Remove lock washer, lug and bracket from bolt.
10. Discard lug, and replace with a new unit.
11. Using a new 18' length of RG/58, push end of new coax into the coax hole on side of plastic cover, and pull 6 to 8 inches inside for an easy working length.
12. Trim this end of the coax until the following is exposed:
Center conductor: 1/4" Foam covering: 1 1/2" Shield exposed: 3/4"
13. Tin, with solder, the 1/4" exposed center conductor.
14. Tin, with solder, the 3/4" of exposed shield.
15. Insert bolt, with plate washer, through bottom of magnet plate hole.
16. Install SO-239 bracket on bolt extending through hole.
17. Install new lug onto bolt through SO-239 bracket.
18. Install internal tooth lock washer, then nut onto the bolt.
19. Re-tighten nut for secure fit.
20. Insert tinned center conductor into center pin hole of SO-239. Bend at a 90 angle, and fill hole with solder.
21. Insert tinned shield into the cleaned lug hole and solder.
22. Warning: clearance is very tight. Visually check to verify that no strands of shield or center conductor is shorting out, then use an ohm meter to verify. Also check for poor or "cold" solder joints.
23. Place cable tie on coax cable inside plastic cover, one inch from end of coax rubber covering. Tighten securely, as this will provide a strain relief for the coax cable to prevent cable from pulling out of mount. Trim off excess tie wrap.
24. Pull excess cable through hole until strain relief is against inside of plastic mount cover.
25. Slip cover over magnet housing, and press to fit tightly against completed assembly.
26. Install lock washer, nut, then tighten securely.
27. Install a new PL-259 on radio end of coax cable.
C. Wilson 500 Magnetic Mount
The Wilson 500 coil is not removable from the mount, therefore the replacement of coax cable is vastly different, but can be easily accomplished.
1. Turn antenna upside down so the bottom covering is facing you.
2. Cut an X configuration at the center, and carefully fold back the cuts, to expose the 9/16 hex bolt head. NOTE: A new vinyl pad is available from wilson if desired.
3. Using a 9/16" socket, loosen and remove the bolt.
4. This will cause the magnet plate to fall free from the antenna, and expose the underside of the antenna. Notice that the center conductor of the coax cable feeds into the coil and is not accessible.
5. Cut the old coax cable at a point between the cable tie wrap (strain relief) and the exit hole.
6. Pull old coax cable free and discard.
7. Cut cable tie wrap from remaining coax cable portion.
8. Remove outer rubber covering and shield from coax cable by sliding it off from the remaining coax. This will leave only the foam covered center conductor.
9. Cut this center conductor to a length of 1 1/2".
10. Trim the foam covering to expose 1/2" of center conductor.
11. Insert a new 18' length of RG/58 coax cable through hole in plastic cover, and pull 6 to 8" inside for an easy working length.
12. Trim this end of the coax until the following is exposed:
13. Center conductor: 1/2" Foam covering: 1/2" Shield exposed: 1/2"
14. Tin both exposed and trimmed center conductors.
15. Splice the center conductors together by inter-wrapping them together, then soldering the connection.
16. Starting 1/2" above soldered wire, wrap electrical tape around the foam conductor to a point 1/2" below
soldered wire.
17. Repeat to ensure a double covering of tape over the cable.
18. Solder a new lug onto the trimmed shield.
19. Place cable tie on coax cable inside plastic cover, one inch from end of coax rubber covering. Tighten securely, as this will provide a strain relief for the coax cable to prevent cable from pulling out of mount. Trim off excess tie wrap.
20. Pull excess cable through hole until strain relief is against inside of plastic mount cover.
21. Visually check to verify that no strands of shield or center conductor is shorting out.
22. Place lug's center hole over threaded hole of coil housing.
23. Carefully replace magnetic plate on bottom of antenna.
24. Screw 9/16" bolt through bottom of magnetic plate hole and into coil.
25. Securely tighten with 9/16 socket.
26. Fold down cut slots of vinyl trim, so that the bottom portion is stuck to the bolt.
27. Install a new PL-259 on radio end of coax cable.
D. Wilson Little Wil Magnetic Mount
1. Turn antenna upside down so the bottom covering is facing you.
2. Cut an X configuration at the center, and carefully fold back the cuts, to expose the 1/2" hex nut.
3. Using a 1/2" socket, loosen and remove the hex nut and lock washer.
4. Remove chrome mast from the top of the antenna.
5. Remove small rubber washer from threaded top bolt.
6. Carefully peel back the outer edges of the black vinyl pad covering the bottom, so that the magnetic plate is loose.
NOTE: A new vinyl pad cover is available for replacement use if desired.
7. Using a pair of needle nose pliers, forcefully pull keeper from base cover. (This is at the coax cable entry point, and located directly beneath the coax.) Pull coax loose from housing.
8. This will cause the antenna to disassemble into three separate pieces: the magnet plate, the coil, and the black plastic housing
9. At the bottom of the coil, remove shield lug on bolt.
10. Unsolder center conductor from coil wire.
11. Remove black electrical tape protecting capacitor.
12. Unsolder capacitor from the center conductor.
13. Cut capacitor loose at shield lug, and discard old coax.
14. Prepare a new 18' length of coax with the following exposed:
Center conductor: 1/4" Foam covering: 1" Shield exposed: 1/2"
15. Insert the exposed shield lead and one end of the capacitor into the eyelet of a new lug, and solder.
16. Solder both the exposed center conductor of the coax and the remaining end of the capacitor the coil wire.
17. Check to verify that the solder joints are good and do not have any "cold" solder joints.
18. Cover capacitor and exposed bare leads with electrical tape.
19. Slide shield lug back onto bottom coil bolt.
20. Place a cable tie on coax cable, one inch from end of coax rubber covering. Tighten securely, as this will provide a strain relief for the coax cable to prevent cable from pulling out of mount. Trim off excess tie wrap.
21. Re-insert antenna coil back into housing.
22. Install rubber washer and chrome mast on top, and tighten securely.
23. Install coax cable so that it is tight and inserted into channel.
24. Apply a small amount of glue to the sides of the plastic coax keeper, and re-insert fully into slot.
25. Carefully replace magnetic plate on bottom of antenna.
26. Place lock washer on extending bottom bolt, and screw 1/2" nut onto bolt extending through bottom of magnetic plate hole.
27. Securely tighten with 1/2" socket.
28. Fold down cut slots of vinyl trim, so that the bottom portion is stuck to the bolt. Reseal outer edges of vinyl pad to bottom of magnet.
29. Install a new PL-259 on radio end of coax cable.