How to attach PL-259 connectors to 0.42" & 0.5" OD 75 ohm aluminum jacketed hardline

Materials required: PL-259 connector (preferably Teflon & silver plated)
1/2" brass tubing (Small Parts catalog.# U-TTRB-15)
17/32" brass tubing (Small Parts Catalog # U-TTRB-16)
1/2:" SS hose clamp (Small Parts Catalog # U-CHX-5)
Tin-lead solder
Zinc oxide compound (Penetrox, etc.)

Tools required:

200 watt solder gun
Dremel high speed cutting tool
Thin width Dremel cutting disk
Technique:

Cut one-inch lengths of the 1/2" and 17/32" brass tubing using the Dremel tool and thin cutting disk. (a tubing cutter is not recommended. It would cause the brass tubing to constrict and make the fit difficult) The rear of the PL259 barrel will need to be ground out a little as shown in the photos in order to slip over the brass tubing. Place the parts together as shown in the photos and solder. Cut two slits in the 7/16" tubing as shown. Prepare the coax as shown Place a light coating of Penetrox (zinc oxide compound found at electrical supply houses) on the aluminum jacket that will be inside the brass tubing. Place connector on the coax and secure it to the connector using a ½" hose clamp and solder center pin. Don't forget to put the PL259 barrel on before applying the hose and soldering the center pin.

How to attach PL-259 connectors to 1/2" OD 75 ohm CATV aluminum jacketed hardline

Using similar techniques, the PL259 can easily be attached to ½" 75 ohm CATV hardline coax In this case, a single 1" length of 17/32" brass tubing is cut, slipped on the end of the PL259 and soldered (17/32" slips perfectly over the ½" coax aluminum sheath). Cut two length-wise slits in the open end of the brass tubing. This allows complete compression. Finally, secure with a ½" hose clamp. Again, use Penetrox to lubricate the aluminum/brass surface connection (don't forget to slip the PL259 barrel on before clamping and soldering the center pin. The rear end opening of the barrel will need to be enlarged by grinding it out a little as shown, in order to let it slip over the brass tubing.


Design by Dave, W5UN