1" OD Swaged/sweged end aluminum tubing? - AVS Forum | Home Theater Discussions And Reviews
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post #1 of 7 Old 11-22-2019, 06:56 AM - Thread Starter
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Question 1" OD Swaged/sweged end aluminum tubing?

I am in the process of preparing for a full rebuild of a CM-1100.

I have been going to various tubing suppliers and am not have any success in locating the product.
The basic problem is that if I purchase 12 foot lengths of 6061-T6 or any tubing of that length the shipping pops up to over 125.00.
8' falls under the bump freight charges as well.

The booms on the 1100 are just over 11 feet long. The CM-1160A is long and uses swaged tubing.
So my plan to save on the shipping is to use 6' swaged tubing and oppose the swaged ends. It would give a little over 2 foot offset which may be enough to prevent any sagging.

Or if the supplier would cut the maximum length allowed that would not require freight. Which would be just under 8 foot that would be even better as the off set between the swages would increase by quite a bit.

Does anybody have any links to suppliers that specifically sell swaged aluminum tubing?

My other option would be sleeving 1" ID over 1" OD. The tolerances would need to be tight though.

Thanks guys.

Last edited by MSev; 11-22-2019 at 08:19 AM.
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post #2 of 7 Old 11-22-2019, 08:54 AM
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Does anybody have any links to suppliers that specifically sell swaged aluminum tubing?

My other option would be sleeving 1" ID over 1" OD. The tolerances would need to be tight though.

Thanks guys.

I don't know where the ham antenna manufacturers get their swaged tubing from but you can get telescoping tubing from DX Engineering with/without end slits.

https://www.dxengineering.com/search...rder=Ascending

You can use hose clamps on the slit ends or sheet metal screws to hold the pieces.

All the DX Engineering tubing has 0.058" walls which allow the next size up or down to telescope without binding. You cannot slide a 1" OD tube into a 1" ID tube. There's no chance this will work and filing the hole larger is a nightmare.

Shipping costs for long tubes is insane. DX Engineering should have the lowest costs.

I'd get a can of their anti-seize compound should you ever want to disassemble the boom.

https://www.dxengineering.com/search...rder=Ascending

Although I don't think swaged tubing is necessary, if you insist I'd call M2 Antennas and ask if they would sell you the tubing. I think the sizes you're looking for are pretty standard.

https://www.m2inc.com

They use swaged tubing that joins equal OD tubing together.

Last edited by Calaveras; 11-22-2019 at 08:58 AM.
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post #3 of 7 Old 11-23-2019, 07:00 AM - Thread Starter
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Quote:
Originally Posted by Calaveras View Post
I don't know where the ham antenna manufacturers get their swaged tubing from but you can get telescoping tubing from DX Engineering with/without end slits.

https://www.dxengineering.com/search...rder=Ascending

You can use hose clamps on the slit ends or sheet metal screws to hold the pieces.

All the DX Engineering tubing has 0.058" walls which allow the next size up or down to telescope without binding. You cannot slide a 1" OD tube into a 1" ID tube. There's no chance this will work and filing the hole larger is a nightmare.

Shipping costs for long tubes is insane. DX Engineering should have the lowest costs.

I'd get a can of their anti-seize compound should you ever want to disassemble the boom.

https://www.dxengineering.com/search...rder=Ascending

Although I don't think swaged tubing is necessary, if you insist I'd call M2 Antennas and ask if they would sell you the tubing. I think the sizes you're looking for are pretty standard.

https://www.m2inc.com

They use swaged tubing that joins equal OD tubing together.
Single 12 foot lengths of 6061-T6 would be preferred.
However if I wanted 2 12 foot sections the shipping would be 128.00 for 48.00 worth of tubing.

I had looked through DX Engineering and had missed the nesting ability of the .058 tubes.

I have been searching through the .068 6061-T6 on other sites to sleeve over with the next size larger since the swaged didn't appear to be present.
As you say the swaged isnt necessary. What I wanted to do was match CM's tubing.
Nesting a 6 foot section of 0.875 in. OD should stiffen it up quite a bit and only add a little over 1lb.

Just have to come up with some end caps for the tubing.

I would through bolt the sections with stainless.
Anti-seize is invaluable when working on machinery. Use it all the time.
I would imagine the Mariner's Choice would be the way to go.

I have a small stack of quantums laying around now. I believe there are enough parts and brackets I believe for 2 builds.
My intent is to add the extra floating directors and extend the nose piece much like 300ohm or Stampeder did years ago to get extra gain.

I had a little escapade a couple of month ago involving a 1100 that was in great shape until the telephone it was mounted on snapped off at the ground from underneath me.

Oh yah. That exciting. The home owner thought I died and was impress with me dropping the pole on her house. LOL.
Funny thing is. None of the directors or plastic connectors for the elements on the nose or floating directors broke. Cant say the same for many of the elements or the booms.

Currently the booms are curved almost perfectly for rebuilding a 4251 I recently picked up. Dont try this technique at home.
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post #4 of 7 Old 11-23-2019, 12:42 PM
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Single 12 foot lengths of 6061-T6 would be preferred.
M2 antennas are using 6063-T832 and they are among the best antennas that exist. There must be a reason why they're using that material because they don't cut corners.
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post #5 of 7 Old 11-23-2019, 02:13 PM - Thread Starter
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M2 antennas are using 6063-T832 and they are among the best antennas that exist. There must be a reason why they're using that material because they don't cut corners.
Well I cant argue with that.
I'll check in with them. See what they off and what the pricing is like.

Just a matter of hunting everything down.

These guys are supplying Aircraft Grade 6063-T6
But it looks like their selection may be limited.
http://www.antennapartsoutlet.com/Pa...EbhyJvggA8O2ww

This group is offering cut length up to 7' 11". But in 6061 T6. It would be nice to have to offset the joints.
Unfortunately they dont appear to offer the .058 wall. So nesting the .875 is a not go.
https://stockcarsteel.com/aluminum-t...m-round-tube-1
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post #6 of 7 Old 11-23-2019, 05:56 PM
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Well I cant argue with that.
I'll check in with them. See what they off and what the pricing is like.

Just a matter of hunting everything down.

These guys are supplying Aircraft Grade 6063-T6
But it looks like their selection may be limited.
http://www.antennapartsoutlet.com/Pa...EbhyJvggA8O2ww

This group is offering cut length up to 7' 11". But in 6061 T6. It would be nice to have to offset the joints.
Unfortunately they dont appear to offer the .058 wall. So nesting the .875 is a not go.
https://stockcarsteel.com/aluminum-t...m-round-tube-1

Onlinemetals.com offers 6061-T6 cut to length and various wall thicknesses including 0.058" but their prices are high. DX Engineering is much less expensive.
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post #7 of 7 Old 11-24-2019, 06:48 AM - Thread Starter
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Onlinemetals.com offers 6061-T6 cut to length and various wall thicknesses including 0.058" but their prices are high. DX Engineering is much less expensive.
I have noticed the various differences. It is unfortunate.

What I found interesting is that UPS, USPS and fedex have a max shipping length of 108 inches of combined length and girth.
If ordering 1 1" OD pipe. There should be no freight charges.
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