Extreme Experiment: Melting Antennas For Science

1,500 Watt QRO Challenge! In this video, I'm trying to melt some plastic to test some new antenna material. I'm using Ecoflex 15, which is a very heavy duty coax. I'm also using a RatPack switch from Array Solutions and I'm showing you how I'm trying to melt the plastic with my Acom 2000 Amplifier. Can it handle this power? Tune in to see the entire process! Callum.
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[@keithnolan-fns]

When doing something similar before, I stuck the part in a microwave oven to see if RF wigglies would heat/melt it. Great vid, Cal!

[@DXCommanderHQ]

Tried that Keith.. Unfortunately, not a good experiment. I could hardly get the black stuff warm in a microwave BUT burst into flames on 20m.

[@HamRadioDX]

Great video Cal, love seeing a bit of experimenting, all in the name of science :)

[@DXCommanderHQ]

Great fun Hayden!

[@wolfhawg]

Cal you are a true ham. Always work on antennas in the winter. 73s

[@DXCommanderHQ]

Yes indeed!!

[@DonzLockz]

Great practical testing with "melting energy" Callum. Glad it was a success.👍

[@DXCommanderHQ]

Thanks 👍

[@G6EJD]

In its simplest terms it’s ohms law and power calculations. The DX10 cable of 24/0.2mm2 is rated at ~14A continuous and most insulation is good for 600V. Therefore 1600W of power into a 50R load is comprised of 5.65A and 283v and that’s well within the specification of the materials used. The Teflon plates have an extremely high resistance and will never be affected. In most cases the coaxial cable will be the limiting factor but that’s not the antenna. Even doubling the power level to 3200W will still be within the wire specification, it’s an excellent and rugged design.

[@DXCommanderHQ]

David, yes - good reminder of the calculations there - we do experience a heat-gremlin at the top of a regular foldback on higher frequencies.. The work-around is a closed loop - like I made when I soldered the top on this one.

[@GSWEAR66]

Awesome content Callum, thank you!!

[@DXCommanderHQ]

My pleasure!

[@craigstothard7518]

Dogs are like, " we have been in and out like Fiddlers elbow!!"

[@DXCommanderHQ]

Yes!!

[@robertbird7297]

I have seen someone transmit HF power into a string of Christmas lights. They were able to answer the question about where along the string the lights are the brightest.

[@ham-radio]

That was me, Jim W6LG on my front deck on Wolf Mountain in California. 73, Jim

[@tobiasgertz7800]

"It's s pipe I put the wigglies through." Story as old as time.

[@DXCommanderHQ]

Yes!

[@randyhavener1851]

The puppies are looking good! Thanks for letting us follow your experiment!! Have a wonderful day Callum!! N9RAN

[@DXCommanderHQ]

Thanks! You too!

[@dl4qb-andre938]

Thumbs up for the Acom 2000A! I´ve the same and that box can handle full power at unlimited time! I never will sell it :-)

[@DXCommanderHQ]

Me neither!

[@ScatManAust]

What would be interesting for extra experimenting is how it would go when the ambient temperature is around 45 degrees to start off with. Obviously would be hard where you are but 45 degrees this neck of the woods is common.

[@eddieMurphy11111]

it never cesses to amaze me what such thin wire will stand up to i used to talk to a man in Spain and he was using thin speaker wire to transmit on , thanks for the video

[@DXCommanderHQ]

Hey, I'm the same!

[@eddieMurphy11111]

@@DXCommanderHQ he was running just 50 watts eddie G0VVT

[@charlieoscar09]

You have the look of Freddy Krueger

[@DXCommanderHQ]

HAHA

[@alallan7584]

I worked in a plastic factory who made many different types of plastics for food wrap. When making black or plastics of solid color, a pigment was added to the resin mix. This color pigment was made with metal. I think it was light metal such as titanium. So, for color, might have to go with a die.

[@DXCommanderHQ]

That's right.. It's always the pigment.

[@ZeroHarry]

I think the term you are looking for is SPI (squiggly per square inch) 🙂 or WPI (wiggly per square inch)

[@DXCommanderHQ]

That's it! WPI :)

[@m7trsradio]

Nice R&D Callum. 👍🏻

[@DXCommanderHQ]

Thanks 👍

[@proudsnowtiger]

Thermal camera next time? That'd be fun - you could see all sorts...

[@DK5ONV]

Just love these beautiful Dogs 🤗😍💯🙋‍♂

[@g4lmn-ron401]

High current and low volts at the feed, high volts and low current at the end, so the power is roughly the same all along the wire, I would expect the block at the feed end to be the most vulnerable. The volts that jolts but the mills that melts. You should do the test in the summer when it's 30C+. And you should do it three times to prove the result wasn't a fluke. Fun stuff!

[@DXCommanderHQ]

Ron, this is about the 8th time we've done this in total. The very end of the wire melts on 28MHz unless we make a "QRO" loop. So says something about something.. Just not sure what!

[@g4lmn-ron401]

@@DXCommanderHQ It's the high voltage at the end, the opposite to what I would expect. That's what makes all this interesting.

[@vojtechplzensky2472]

It is melting at the top exactly because the electric field is the strongest there. The insulation and plastic bits do not react to magnetic field and do not conduct any current but they do change on microscopic level in the electric field. These changes are not lossless. Dielectric loss is important parameter in capacitors.

[@brucecash3939]

Enjoyed the video. Keep on experimenting

[@DXCommanderHQ]

Thanks, will do!

[@edcozart9916]

This is whats disappointing about R&D when everything goes as planned and no smoke 🤦‍♂🤦‍♂🤦‍♂ but on a good note we will get a better product in the end Thanks Callum cheers from across the pond W9US

[@mirko9a6kx32]

I'd try to messup SWR a bit, lets say 1600W out and 300W back to the limit of amp protection mechanism - to see if that melts easier on 10m :)

[@DXCommanderHQ]

Haha Mirko! The 2000 shuts down on 575W return power :)

[@3dPrint_and_chill]

1500w on FT8?! My god 😆. I know it's technically a weak signal mode not a low power mode, but damn.

[@DXCommanderHQ]

I know!

[@cliffyoung5712]

Cal, are you going to make plates for the 12.4? I would like a set. Its going up permanently.

[@DXCommanderHQ]

Yes. dxcommander.com/product/12-4m-plate-set/

[@J1mbo888]

Great work as always Cal 🙂

[@DXCommanderHQ]

Thank you! Cheers!

[@ke8wlw]

that guy in bulgaria sounded fantastic. very reassuring that a dx commander is 100% quality!

[@DXCommanderHQ]

Yes, he was amazing.

[@mickeylessley1684]

9 mo. late. But crazy fun. I got a kick out of this. Carry on.

[@DXCommanderHQ]

9 months is fine.. I'm still here :)

[@jimbronson687]

Well I no little about these radios. Lots about particle physics. I have to ask. What did those blocks with holes on each end?? What are they for what is the reason for them??

[@DXCommanderHQ]

Jim.. It is just a style of plastic that I want to make the plates out of.. I slipped them onto the element to see if they will stand the energy.

[@jimbronson687]

@@DXCommanderHQ I heard you say that. Just was not sure what it could be useful for other than a gallayo themometer type use OK cool thamk you

[@Paul_VK3HN]

What's the power limit on UK hams? 😉

[@pjo7281]

and why do UK hams need 2000 watt amps? ;) lol

[@DXCommanderHQ]

400W Paul (unless you have a commercial licence).

[@DXCommanderHQ]

@@pjo7281 A bit like why does your car go 120MPH when the limit is say 70? It's called an engineering margin. You don't want to run your 100W radio at 100W FT8 either - you would melt it. Or do RTTY at 400W - you would need probably 4 times that amount to do RTTY at 400W. Think things through rather than regurgitate baloney you read on Facebook.

[@jeffmerlin2580]

4:26 The worlds most accurate tape measure? Funny! 🙂

[@DXCommanderHQ]

I should really be more accurate!

[@anthonyrosa5006]

I think you need complete mechanical decoupling on top of other sound suppression methods to stop bass from transmitting. I'm a bass player. A free-floating cube in a vacuum. I used to piss off my neighbors when I was a teenager. They would bang on the wall and blast their radio and I would crank it up. I was a nasty prick. I guess they got used to it and I kept it fairly loud but not abusive.

[@DXCommanderHQ]

Indeed. It's a tough act.

[@the_mad_swimbaiter455]

Will it or won't it... watching to find out!

[@stirlingpark6145]

Van Morrison lives...!

[@brianhoran610]

Hi callum I got Dx commander classic with 41 ground radius on gravel will it work better if the radius are covered over with gravel or by artificial grass

[@DXCommanderHQ]

Brian, won't matter. Just make it look nice - or to your satisfaction..

[@rfengineer3]

I wish I could download the data in your brain into mine... lol

[@DXCommanderHQ]

I would be scary. I promise you!

[@jessemazo4791]

idunno why that trips me out a little bit lol ..i say its coming from overseas, and you say coming from the states. pretty cool man... cheers to diversity!

[@WX4CB]

@8:40 - Looks like you're going to need another set of crimpers sent to you :D - i'm assuming that's delrin? looks like it... I use that stuff as insulators for all my antennas :D

[@DXCommanderHQ]

Similar..

[@geoffmcwiggan2814]

Give it heaps of wattage old mate 👍🇦🇺

[@Frankh77]

"For science" :) That's what we say in the states, when we blow stuff up.

[@DXCommanderHQ]

Ah!

[@Trent28888]

The sparks u were thinkin of is called ionisation due to capacitance like a tesla coil but will u still be sellin the white plates or just the conductive grey?

[@DXCommanderHQ]

Eventually, we will move to grey.

[@chrisbartlett6022]

Veeeeeeeery Innnnteresting 🙂

[@genoa1979]

Nice not go in flame 💪🏻😉

[@DXCommanderHQ]

You got that right!

[@dieterbuschbaum6904]

well had a Weekend of fun watching your videos...73s M7DMB

[@trevorhardisty6255]

Hi Cal, I love your "lets try this and see what happens" way of thinking, Also what breed are the dogs? 73's Trevor ZL1UTH

[@DXCommanderHQ]

Hiya Trevor.. So both the pups are Labradoodles.. Mostly Poodle with some Labrador

[@VK4VO]

1500w on 10mtrs FT8 is insane,,, thats an amp killer, moreso if its a SSA.

[@48pluto]

I have an idea. Place some steel wool around the antenna wire in a few places. The HF should heat up the steel wool. Maybe burn it.

[@DXCommanderHQ]

That might be fun!

[@DeltaXray444]

Place a mobile phone inside a ring of steel wool.. Brillo Pad guage.. now call that phone and watch the steel wool burst into flames.. Makes you wonder what all that sporadic RF is doing to our brains..

[@KillerSpud]

"do you ever ever do anything terrifying?" Yes, bringing up a 250kw wireless charging system. And our up-coming 500kw system is going to be worse. They should be fine but the ominous 60hz hum coming out of the power supplies is pretty butt picking.

[@DXCommanderHQ]

Woo-Hoo!

[@G1WHP]

Hello..why have you removed from the group. I have been extremely unwell but I’m getting better very slowly I’m trying a bit of radio hope to catch you soon Paul

[@DXCommanderHQ]

Hello Paul! Yes mate, I know you have been unwell. Carl and I have done NOTHING about the old WhatApp group. I assume it's still there. I changed my phone last year so no idea old mate! Anyway, I remember your problem, bloomin nightmare old chap. Call in anytime or drop me a text!

[@sierge1]

Good God Callum, 1600 wattss were you trying to work the moon? LOL. Mike/K1EG

[@DXCommanderHQ]

Yes!

[@joeblow8593]

I'd like to see you burn the antenna into resonance

[@DXCommanderHQ]

Soon Joe. I need to try that.

[@kelvin0mql]

Find someone working CW, transmit a 1500w carrier right on him. Real nice.

[@DXCommanderHQ]

Yeah.. I moved - then he came up..! I need three eyes!

[@kelvin0mql]

@@DXCommanderHQ LOL... sneaky buggers.

[@mewrongwayKOCXF]

Wonder if a guy could make a living melting antennas? lol Hi Callum

[@DXCommanderHQ]

HAHA

[@robertabbott7770]

Where were the explosions , and flames !!!!!!!🔥🎆 🤣 Cancel the Hollywood FX job .

[@DXCommanderHQ]

Woops!

[@mewrongwayKOCXF]

Ya like a tin can in a microwave or something! lol

[@JoshColletta]

The bad news: nothing actually melted. The good news: nothing actually melted.

[@DXCommanderHQ]

That is one good way of looking at it!

[@scratchpad7954]

I would exceedingly recommend you to get RG-6 or RG-11 coax. Not only is it one of the least lossy coaxial cables you can get, but you can also use it in a pinch for your television receiver. Also, the losses are completely negligible at 14 MHz, and could easily handle 2 kW.

[@g0fvt]

Although 75 ohm cable will be fine in a number of situations it is a nuisance if you are doing R&D work for 50 ohm systems. RG11 does have some interesting ratings though.

[@DXCommanderHQ]

I don't see what's wrong with EcoFlex 15. Higher rating and less lossy? And more importantly.. I already have it!!

[@malechauvinist6460]

your hat is scary. you look like the guy that locked grandma in her forever box.

[@DXCommanderHQ]

I did!

[@G6EJD]

Tin Whiskers are a real problem for those who are interested and can account for many failures.

[@DXCommanderHQ]

You may be right!

[@tommiehinman1349]

2500w will set the insulator on 14ga on fire on 80m on a 80m dipole

[@DXCommanderHQ]

I wonder how we know :)

[@tommiehinman1349]

@@DXCommanderHQ oopsie

[@patrickbuick5459]

I would expect highest current has highest heating, highest voltage tests the dielectric properties.

[@DXCommanderHQ]

I know.. But what we expect - and what happens doesn't seem to correlate!

[@patrickbuick5459]

@@DXCommanderHQ Sounds like you are describing dating and marriage!

[@dback4430]

Now put all the elements as if you remember I had 40 arc to 80 or vice versa. It was a one off this far and way less power.

[@DXCommanderHQ]

Yes, you were an odd ball (well.. not YOU but the problem).. We've never managed to replicate that ever againi or by any other user.

[@dback4430]

@@DXCommanderHQ No I am a bit odd , but I haven't had that issue again .

[@1shARyn3]

WSPR - 2 minutes (roughly)

[@DXCommanderHQ]

AT 1,500W LOL yes OK, that sounds like a GOOD TEST!!!!

[@roach1317]

Blow it up. Cal

[@DXCommanderHQ]

I actually WANTED TO! :)

[@gvii]

Shame you couldn't get it to go to goo, would have been fun to watch if you had. On the other hand, it is good to know you can safely use it for whatever without setting everyone and everything on fire, hahahaha....

[@DXCommanderHQ]

I know.. I was half-expecting it to dribble!

[@danielstimpson7792]

An antenna man who "isn't interested in coax" ?

[@DXCommanderHQ]

I have an interst - but it's just a means of getting A to B with energy :)

[@FjHenderson]

1500 watts using ft8! WTF would anyone use 1500 watts with ft8, that is totally stupid. I've heard of operators doing that and you don't need that much power using ft8, a digital mode. Then they turn it on and leave it and wonder why there amplifier is junk.

[@DXCommanderHQ]

I have to cater for "stupid" I'm afraid.

[@FjHenderson]

@DXCommander I bought an acom 2100 and it worked but after I got it home I noticed it actually wasn't working at 100%. I got a new tube for it and no difference and it got worse. When I changed the tube all of the silver in the tube compartment was purple and had been overheated. I ended up sending it to array solutions and they figured it had been run using ft8. They had to get a new controller board from acom. The amplifier is only 2 years old. It would have been cheaper to buy a new acom like yours

[@geoffmcwiggan2814]

Wind it up Cal….. POWER. !!!! 😜🇦🇺

[@BigBoss-rh7zq]

No much scientific test.

[@DXCommanderHQ]

I had no idea that two years of research, fires and other failures, would amount to 'not much' of a scientific test. Glad I wasn't in your class!

[@BigBoss-rh7zq]

@@DXCommanderHQ Don't want to offend you. I have not understand why you have placed that kind of plastic in such a way and what did you expect form that. Looks to me that the plastic sheath of the wire (likely pvc) works just fine as your grey stuff.

[@DAVIDGREGORYKERR]

27,000,000hz(27Mhz) is close to the resonet frequency of Chlorine Atoms.

[@DXCommanderHQ]

Well, THAT's bloomin handy!

[@dennis8019]

u use the coax for a test on 2.4 with a PL 259. thought they were not rated for that frequency.. anyway cool video again ....

[@DXCommanderHQ]

Those ends can be swapped out in seconds for N types.

[@davidw460]

Hi Cal - another simple test is to take the new insulator over to the microwave and give it a cook. If it stays cool then it might be ok 🎉 G5YAX

[@DXCommanderHQ]

That's the problem.. I did that with the black stuff.. AFter 5 mins, it was barely warm.. But on 20m, we had flames inside 30 seconds!

[@DedyBlackLaBeneamata]

nice experiment, may we can contact in 11m #indonesia

[@DXCommanderHQ]

Sure.. If you can ever hear me on 10m, shout on the stream and we can go down to 11m on 12W.