Ham Radio EMT Conduit Antenna Mast

This post is about how I built a 19-foot ham radio antenna mast using (EMT) Conduit, then extended that mast to 28-foot using a Chain-Link Fence Top Rail.

You can see the 28 ft. EMT Conduit antenna mast below, it's the mast without an antenna.

ham radio EMT conduit-chan link fence top rail antenna mast

1. Part List
2. Instructions for building the mast
3. Building notes
4. Safety considerations
5. Conclusion
6. Reference Links

Part List:

1. One 1-1/2 in. x 10 ft. (EMT) Conduit
2. One 1-1/4 in. x 10 ft. EMT Conduit
3. One 1-3/8 in x 10 ft. Chain Link Fence Top Rail
4. One 1-1/2 in Conduit Pipe Hanger
5. Two Stainless Steel Hose Clamps
6. One 3/4 in Galvanized Pipe Hanger Strap
7. One Rustoleum spray paint Color your chose
8. Additional hardware rope, pulleys, L-brackets and Stainless Steel Hose Clamps

Instructions for building the mast:

Spray paint all the (EMT) Conduit - Chain Link Fence Top Rail.

Part 1. Build the 19 ft. EMT Conduit Mast

Step 1. First section 1-1/2 in. x 10 ft. (EMT) Conduit.

1-1/2 in. Conduit Pipe Hanger

Notch one end of the 1-1/2 in. Conduit, to except the 1-1/2 in. Conduit Hanger

Example

Step 2. Second section 1-1/4 in. x 10 ft. EMT Conduit.

Flare out one end of the 1-1/4 in. Conduit to fit snug within the 1-1/2 in. Conduit

ham radio antenna mast Insert the 1-1/4 in. Conduit 1 ft. into the 1-1/2 in. Conduit. Then tap the Conduit Hanger into the notch's of the 1-1/2 in. Conduit and snug up the nut

Insert the 1-1/4 in. Conduit 1 ft. into the 1-1/2 in. Conduit
Then tap the Conduit Hanger into the notch's of the 1-1/2 in. Conduit and snug up the nut

Example

Now tighten a Hose Clamp around the 1-1/4 in. Conduit

ham radio antenna mast A good step Mast 1-1/2in - 1-1/4 in. 19 ft.

Ham Radio 19 ft. Antenna Mast 1-1/2 in. - 1-1/4 in. EMT Conduit.

Part 2. Extend the Mast to 28 ft. with a Chain-Link Fence Top Rail

Step 1. Third section 1-3/8 in. x 10 ft. Chain Link Fence Top Rail.

1-3/8 in. X 10 ft. Top Fence Rail

Put a small screw 1 ft. 6 in. down from the top of the 1-1/4 in. Conduit
This is the stop for the 1-3/8 in. Top Rail

Fabricate a shim out of some Pipe Hanger Strap

ham radio antenna mast Insert the taperd end Top Rail into the 1-1/4 in. Conduit. Then slide the Pipe Hanger Strap sim between the Top Rail and the Conduit

Insert the taperd end Top Rail into the 1-1/4 in. Conduit
Then slide the Pipe Hanger Strap sim between the Top Rail and the Conduit

Now slip a Hose Clamp over the Pipe Hanger Strap shim to keep it in Place

ham radio antenna mast A good step Mast 1-1/2 in. - 1-1/4 in. 1/3/8 in. 28 ft.

Ham Radio 28 ft. Antenna Mast 1-1/2 in. - 1-1/4 in. EMT Conduit 1-/3/8 in. Fence Top Rail

Building notes

The 3/4 in. Pipe Hanger Strap shim is a little tuff to slip between the Conduit and the Top Rail.
I had to squeeze the 1-1/2 in. Conduit Pipe Hanger some and from the image you can see the 1-1/2 in. Conduit flared out some.

Safety considerations

Site selection: Never build a mast where it could fall into or make contact with power lines.
Guying is essential: For a mast taller than 20 feet, especially if using a light material like EMT, guy wires are not optional-they are critical for preventing the mast from buckling and failing.
Partner: Do not attempt to erect a tall mast alone. It requires at least two people to lift and secure it safely.
Overload: Do not use this mast for large or heavy antennas. It is designed for lightweight antennas, such as a wire antenna.

Conclusion

Surprised how easy it was raise the mast, it was not that heavy.
This is a good Home Brew Antenna Mast for wire antennas.