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Rigid radar mount for $115

 

Radar mount

Working on the radar (Halo20+) integration to my boat.

As first, I think it is insane to pay $300-500 and above for the piece of aluminum, even if it is intended to keep $2K radar on the mast.

Some other considerations: All off shelf mounts are UNIVERSAL and have small hinges with pretty small stainless pins (place for galvanic corrosion). To be universal they built with hinges (weak points). 

So I decided to design my own design.

Design ZERO, Plywood mount  

Temporary, VERY temporary - I need 2 hour life time ;-)  LOL

My first radar mount ;-). This mount designed and built from 1/2" plywood ;-). WHY? My boat in the lake now and I plan to move it to Gulf of Mexico at the end of the year. Here, in the lake, no big necessity for the radar on the boat , but I want to check it on the boat, test with my Openplotter and OpenCPN  electronics setup before West Marine return window close.

Plywood radar mount model

Plywood radar mount ready for testing.   

Real mount

Next step will be make real mount.  

My requirements:

  • Mount has to withstand x10 of the radar weight forces in BOTH vertical and horizontal direction without damage. 
    • let say 100kg down + 100kg side load. I think it will faster do fast unexpected disassembling  rather transfer 200kg force on the mount bolts.
  • Design is for my radar and my boat. 
  • Minimum parts - ideally single part.
  • Simple to build. Or orderable.
  • Material - the same as the mast -  Aluminum. 
  • Minimum fasteners. 
  • Cost must not be >$130

My design

Mount designed to be built from single piece of 3/16" (4.7mm) 5052 H32 aluminum.

Design has done as simple as possible.

Part manufacturing quoted $114 in www.sendcutsend.com service. Plus $15-20 priming and painting materials (and I have them on hands).

  

Simulation under stress.

Model survived 200kg load. and geometry deformation did not exceed 2mm. onder the load.

My 200 kg load test  shows only 20% safety margin.

But keep in mind such load may happened ONLY under 25G acceleration or direct hit.  

Normally I expect not more than 5G even in extreme "working" situations. so  have about x4 margin ;-)


Load simulation. 

 

Flattened design


Several 3d views below




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