CRYSTAL SETS TO SIDEBAND

Revision 10, July 2006 

A Guide to Building an Amateur Radio Station

By Frank W. Harris, KØIYE

Copyright © Frank W. Harris , 2002, 2006

Foreword

Table of Contents:

Chapter 1

THE FASCINATION OF RADIO

  • Exploring the shortwave bands
  • Growing up in the Morse code era
  • The joy of building it yourself
  • A brief history of radio communication
  • Henry, Maxwell, Hertz, Tesla and Marconi.
  • Fessenden, Edison, Flemming, DeForest and Armstrong
  • The sinking of the RMS Republic and the birth of ham radio
  • Ham radio in the last 80 years
  • Becoming a radio amateur

Chapter 2

HOMEBUILDING AMATEUR RADIO EQUIPMENT

  • What qualifies as homebuilding?
  • When homebrewing is not appropriate
  • Barriers to modern homebuilding –
  • Time, frequency stability and lead inductance
  • Basic electrical knowledge
  • Magnets & static electricity
  • Voltage, current, resistance, energy and power
  • (Illustrated with drawings of water & mechanical analogies)
  • Conductors, Insulators and semiconductors
  • Capacitors, inductors, transformers & alternators
  • Home power distribution, transformers at low and high frequencies

Chapter 3

SETTING UP AN ELECTRONICS WORKSHOP

  • R&D as recreation
  • How to build radios (or anything else) in your basement
  • Persistence, read books, keep a notebook, & work in small increments
  • Minimum tools needed
  • The ARRL Amateur Radio Handbook
  • Soldering irons and small tools
  • Drills & thread taps
  • Wood carving gouges for making PC boards
  • >50 MHz Oscilloscope
  • Frequency counter
  • Quality multimeter
  • Lab power supply
  • Calculator
  • Lab notebook
  • Collection of electronic junk
  • Parts catalogs
  • Capacitance meter
  • Test leads & socket boards
  • Nice-to-have tools
  • RF & audio generators, spice software & spectrum analyzer

Chapter 4

HERTZIAN WAVES IN THE BASEMENT

  • The nature of radio waves
  • Mechanical and LC electrical oscillators
  • Antenna and transmission line theory
  • Crystal set components
  • LC tuner
  • PN junction diode detectors
  • P-type and N-type semiconductors
  • Detection of AM signals
  • Homebuilding the parts for a crystal set
  • The Jamestown diode
  • The Caribou headphone
  • Recreating Hertz’s radio equipment
  • Transmitting and receiving as simply as possible
  • The 1880 ten-meter communicator
  • Proving that radio waves exist and aren’t just capacitive or magnetic coupling
  • Demonstrating standing waves to measure frequency
  • Building homebrew transistors
  • Bipolar transistors, PNP and NPN
  • Demonstrating voltage gain
  • The Boulder Rock Radio

Chapter 5

GETTING ON THE AIR - DECIDING WHAT TO DO FIRST

  • How to earn a license
  • The rules of the homebuilding game – Whatever makes you happy!
  • Picking an HF band
  • Getting acquainted with the HF ham bands, 160 – 10 meters
  • Instant high quality HF communications
  • VHF/ UHF handheld transceivers
  • Building an antenna
  • Dipoles, regular and folded
  • Multi-band dipoles
  • 80 meters when you don’t have room for a dipole
  • The curtain rod vertical
  • A multi-band vertical antenna
  • Lightning protection

Chapter 6

BUILDING A QRP HOMEBREW

  • A single-band, crystal-controlled, QRP module
  • The transmitter mainframe
  • HF construction methods
  • Making your own PC boards
  • "Dead Bug" and "Gouged Board" construction
  • Superglue "Island Boards"
  • Coax jumpers
  • Shielded boxes
  • The complete QRP crystal-controlled transmitter
  • Transistor amplifiers and oscillators
  • How an amplifier becomes an oscillator
  • Class A and Class C amplifiers
  • Stabilizing the operating point, bypass caps and emitter resistors
  • Quartz crystals – the key to frequency stability
  • The 40 meter QRP circuit
  • Oscillator and buffer
  • Inductors, RF transformers and impedance matching
  • Tapped toroid inductors
  • How to wind them (and mistakes you might make)
  • The final amplifier stages for the QRP
  • Tuned versus broadband - Use both for best results
  • Bifilar wound, broadband transformers
  • How to wind them (and how you might screw up)
  • Ferrite bead RF chokes, expensive RF power transistors, heat sinks & output connectors
  • Conquering inductors
  • Calculating resonance
  • Calibrating trimmer capacitors
  • Calculating turns on powdered iron and ferrite toroids
  • Chebyshev output low pass filters
  • Keying your QRP
  • MOSFET power transistors
  • A "spot switch" for the QRP

Chapter 7

BUILDING A CODE PRACTICE RECEIVER

  • A simple, direct-conversion receiver
  • A great first project for a new ham
  • Excellent sensitivity and good stability
  • Poor selectivity
  • Adding 700 Hz audio filtering
  • High pass and low pass filters
  • Cascaded bandpass filters increase selectivity
  • Operational amplifiers
  • Building with integrated circuits
  • AM broadcast filter
  • Getting rid of the image

Chapter 8

POWER SUPPLIES

  • Line powered power supplies
  • Power supply safety features
  • Isolation, 3-conductor cords, fuses, switches, ratings
  • Supply performance and regulation
  • Rectification, ripple, chokes, capacitors, & bleeders
  • Zeners, linear regulators, switching regulators
  • A QRP regulated power supply
  • A battery power supply for the radio shack
  • Solar cell charging, low drop-out regulators
  • Battery powered shack lighting

Chapter 9

ACCESSORIES FOR THE TRANSMITTER

  • A straight key
  • An electronic bug
  • Building dummy loads
  • "T" type antenna coupler
  • A low pass filter
  • How to stay legal with a homebrew transmitter
  • Antenna and power relays
  • Homebrew QSL cards

Chapter 10

VARIABLE FREQUENCY OSCILLATORS

  • Drift is a big deal today
  • Low frequency VFOs drift less than high frequency VFOs
  • JFET transistors
  • The oscillator circuit
  • The buffer, final amplifier and output filter
  • The 50 secrets of avoiding drift
  • JFETs, single-side PC boards, cast metal box, multiple NPO caps, small variable caps, precision voltage regulation and more
  • Vernier tuning
  • Varactor tuning elements – advantages and disadvantages
  • A precision power supply
  • A voltage doubler power supply for battery use
  • Square wave generator with a multivibrator
  • Squaring up the square wave
  • Charge pump, diode/ capacitor voltage doubler
  • Schottky diodes for efficiency
  • Temperature compensation methods
  • Positive coefficient capacitive trimmer compensation
  • How to adjust the compensator
  • Thermistor/ varactor temperature compensation

Chapter 11

Building a VFO for the higher bands (PMOs)

  • Old approaches that no longer work
  • Frequency multiplication
  • High frequency oscillators
  • PreMix Oscillator method of frequency translation
  • A VFO-controlled QRP module
  • Crystal oscillators are stable, aren’t they?
  • Crystal oscillator circuits
  • Butler oscillators and big crystals
  • Mixers, bipolar transistor and dual-gate MOSFET
  • Optimum drive requirements
  • Direction of tuning, drift error cancellation
  • Multistage filters and filter/amplifiers
  • The QRP final amplifier stages

Chapter 12

FINAL AMPLIFIERS

  • The basic features of a modern linear power amplifier
  • It looked easier in the Handbook
  • Linear "noise mode" operation
  • A tuned 50 watt class B amplifier
  • Ferrite balun transformers
  • An untuned, sort-of-linear, class B, amplifier
  • Keying the 50 watt transmitter
  • A linear Class AB amplifier, this time for sure
  • Single Sideband (SSB) needs a linear
  • Biasing without thermal runaway
  • Clamp diodes prevent runaway
  • Mechanical construction

Chapter 13

BUILDING A HOMEBREW HF RECEIVER

  • Building a receiver - an unusual adventure
  • What’s a reasonable goal?
  • An "adequate performance" HF communication receiver
  • Does it have to be so complicated?
  • Planning your receiver
  • Direct conversion versus superhetrodyne
  • Why not single conversion?
  • Start with a single-band, single-conversion superhetrodyne
  • How do modern digital receivers do it?
  • Receiver construction – build with shielded modules connected by thin coax.
  • The 80 meter preselector
  • Reception on 80 meter and 160 meters is aided by a tuned transmatch
  • The Variable Frequency Oscillator
  • Mixer magic
  • Mixers will give you lots of static – and howls and squeals
  • A practical homebrew mixer made from discrete parts – it’s harder than it looks
  • Dual gate MOSFET mixers
  • Not all MOSFETS work equally well
  • Crystal ladder filters – essential for CW
  • All 9.000 MHz crystals aren’t equal
  • Using the BFO oscillator to match crystals
  • Switch in filters with a rotary switch
  • The IF amplifier
  • The cascode amplifier strip - variable gain with constant Q
  • Automatic Gain Control (AGC) - not a luxury
  • The product detector
  • Nearly anything works at least a little
  • The AF amplifier – a vital part of the signal dynamic range
  • Protecting your ears from strong signals
  • How Hi-Fi should it be?
  • Driving a speaker
  • HF converters for the other ham bands
  • Crystal oscillators
  • Bandswitching
  • Receiver power supplies
  • Use a linear regulator, not a switching regulator

Chapter 14

OLD-TECH VACUUM TUBE RADIO

  • How old can radio technology be and still be used on the air today?
  • Why bother with vacuum tubes?
  • Glowing filaments, colored plasmas & Jules Verne glass envelopes
  • Power supplies for tubes
  • High voltage power supply safety
  • The old-tech QRP transmitter
  • Vacuum tube amplifiers
  • The three roles of the triode filament
  • RF sinewave oscillator
  • Quartz crystals
  • Triode and pentode oscillators
  • Old-tech voltage regulation – big, crude, expensive, but beautiful
  • The travails of triode tubes
  • The oscillator and buffer
  • The final amplifier – triodes chirp
  • The transmitter power supply
  • An inadequate supply from a 1935 radio
  • A good power supply made from cheap, modern, boring parts
  • How to check out junk power transformers
  • A complex but adequate supply made from ancient parts
  • It works! No one suspects it’s old and it’s a success on today’s 40 meter band
  • An old-tech receiver
  • A super regenerative receiver made from ancient tubes
  • The power supply
  • Super-regen on the modern hambands
  • Lots of fun, but not up to modern QRM & QRPs - back to the drawing board!

Chapter 15

THE NOBEL PRIZE FOR SIDEBAND

  • It can’t be that hard! Want to bet?
  • The sideband generator – how it works
  • The 9 MHz oscillator / amplifier
  • The audio amplifier
  • The balanced modulator
  • Building your own crystal ladder filter
  • Decoupling the power supply leads
  • Getting rid of RF feedback - RF filtering for all inputs
  • Tuning and testing
  • Using the generator for AM modulation and CW
  • Moving the 9 MHz SSB signal to a hamband
  • Move the SSB only once!
  • No wonder most ham rigs are tranceivers
  • Moving the 9 MHz signal to the difficult HF hambands
  • Move the VFO first, then mix it with the SSB 9 MHz.
  • Pick your oscillator and VFO frequencies carefully
  • Hearing your own VFO in the receiver
  • The hardest band – 17 meters
  • Covering the widest band – 10 meters
  • A linear sideband QRP, VFO-tuned module
  • All stages must be linear and low distortion
  • All gain stages should be broadband to prevent oscillation
  • Sometimes high pass filter output is needed & not the usual low pass
  • Checking out the generator
  • Driving a 50 watt linear amplifier

Chapter 16

ANCIENT MODULATION

  • Defining amplitude modulation
  • Modulating vacuum tube final amplifiers
  • Plate, screen & cathode modulation
  • A "collector modulator"
  • Converting a MOSFET keyer into a modulator
  • Generating AM with an SSB balanced modulator
  • Compensating for non-linearity
  • Compression by accident
  • You probably don't need to build a compressor
  • Ham TV - The old way.

  • Fun with an ancient flying spot scanner TV camera.

In conclusion:

Homebrew ham radio is never complete - when it works perfectly and does all the latest stuff, the hobby is over. Not likely. Long live homebuilding!

Thanks for reading my book.

73's Frank W. Harris, KØIYE