Ham Radio Install (Round 1)
The next item up on the list was the other half of the comms equation - a ham radio. Not only did I want the radio for trail communications, but I'm also a severe weather enthusiast, and ham is a common method of communication for storm spotters. I took the Technician exam on 12.06.08 and received my callsign on 12.09.08.
Equipment
Radio: Yaesu FT-7800R 2m/70cm ham radio w/ Yaesu YSK-7800 separation kit
Antenna: Comet SBB-5NMO
Antenna Mount: Diamond K400C-NMO lip mount w/ RG-316 coax
Speaker: MFJ-281
I wanted a dual band radio that allowed the face of the radio to be remotely mounted so that I could mount the main 'box' somewhere out of sight; this pretty much narrowed it down to either Yaesu, Icom, or Kenwood. After looking into a few different radios, I ended up deciding on the Yaesu FT-7800R (now obsolete, replaced by the FT-7900R). I wasn't too picky in terms of functionality because I knew that I'd never use even half of what most of these radios are capable of doing. One of the main factors in my decision was the fact that the keys were backlit on the 7800R unlike a number of other radios at the time. I didn't want to be fumbling around in the dark trying to find the right button on a radio whose buttons aren't backlit. Plus the backlight color matches the dash lights on the truck almost perfectly, which is nice. The only other requirement was for the radio to receive the NOAA weather stations, which wasn't asking much since most dual-band mobile ham radios do.
One really nice thing about the coax on the Diamond K400C-NMO mount is the fact that the end connection is a mini-UHF connector (rather than an integral PL-259 connector, which is about 3x as big). This means you can route the coax through a much smaller hole. They include a small adapter that's mini-UHF x PL-259 to allow the coax to connect to the PL-259 antenna port that's on many radios.
Tacoma Ham Radio 02.2009-9.jpg by
soon.enough, on Flickr
I decided that I wanted to mount the face of the radio to the lower dash just below the AC controls because it would allow me to adjust the volume / squelch / frequency knobs while my hand was resting on the shifter. I didn't want to drill holes in the dash to mount the bracket for the radio face, so I decided to test-mount the bracket and face using double-sided tape. This worked ok, but inevitably after a day or two in the heat, the face would slowly droop down. So I decided to make a small custom bracket to hold the radio bracket and face. The back of the bracket matched the contour of the dash, and the front of the bracket had a flat surface and a small 'shelf' to hold the radio bracket. At the time, I had access to a 3D printer, so I just drew the part up in CAD and printed it in plastic.
The bracket still cooling in the 3D printer:
Tacoma Ham Radio 08.2009-1.jpg by
soon.enough, on Flickr
Bracket fully cooled and ready to be broken off of the disposable printing tray.
Tacoma Ham Radio 08.2009-2.jpg by
soon.enough, on Flickr
A quick shot of gray paint and it was ready to go.
Tacoma Ham Radio 09.2009-1.jpg by
soon.enough, on Flickr
Tacoma Ham Radio 09.2009-2.jpg by
soon.enough, on Flickr
Installed the bracket onto the dash with double-sided tape:
Tacoma Ham Radio 09.2009-11.jpg by
soon.enough, on Flickr
Yaesu bracket mounted to the front of the bracket:
Tacoma Ham Radio 09.2009-13.jpg by
soon.enough, on Flickr
The rest of the install was pretty straightforward. I mounted the main radio box under the driver's seat using a 2" x 6" piece of industrial Velcro; it sticks REALLY well to the carpet. And yes, I'm well aware of the potential risks of this...short of the drivers seat being ripped off its mounts, that radio is not coming out from underneath the seat in an accident, believe me I've tried to remove it once.
I routed the coax from the antenna through a plug in the firewall behind the brake booster. This is the same hole I used to bring the power wires for the CB into the cab. Note the CB wires are removed here because the hole was too small for the coax connector to fit through with them in place. I know there's a potential for interference with the two radios wiring routed right next to each other, but my thinking was that I would probably never be transmitting on CB and ham at the same time.
Tacoma Ham Radio 02.2009-2.jpg by
soon.enough, on Flickr
Tacoma Ham Radio 02.2009-1.jpg by
soon.enough, on Flickr
Tacoma Ham Radio 02.2009-11.jpg by
soon.enough, on Flickr
I ran the head unit connection cable (which is a 6P6C RJ12 patch cable basically) under the carpet and up behind the dash. The connection to the radio's face on the dash went through the dash and came out below the AC control panel. I got power to the head unit directly from the battery via the Blue Sea fuse block. I tried the radio out and it worked perfectly the first time. My SWR was below 1.5 on both 2m and 440 MHz.
Crappy cell phone photo of the final result:
Tacoma Ham Radio 05.2009-2.jpg by
soon.enough, on Flickr
I've since changed the ham radio setup a couple different times. More on that later...