CW Optimizer Capacity Hat Kit. 75/80 and 80/40 Thunderbolt Vertical Antennas. for the DXE-7580-THK

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1 CW Optimizer Capacity Hat Kit for the 75/80 and 80/40 Thunderbolt Vertical Antennas DXE-7580-THK DXE-7580-THK-INS Revision 1a DX Engineering 2012 P.O. Box 1491 Akron, OH USA Phone: (800) Tech Support and International: (330) Fax: (330)

2 Introduction This CW Optimizer Capacity Hat add-on kit is especially designed for the DXE-8040VA-1 80/40 Meter Multi-band and the DXE-7580VA-1 75/80 Meter Monoband high performance Thunderbolt TM vertical antenna systems. This add-on kit allows the center of resonance to be moved down to the low band edge for dedicated CW operation. Easy to add to or remove from upper antenna mast with two studded element clamps after lowering antenna. The DXE-7580-THK CW Optimizer Capacity Hat Kit may be added to most antenna designs, including homebrew, to lower the resonant frequency or allow a shorter overall length antenna for the same frequency. Additional DX Engineering Hot Rodz TM are available in different lengths and experimentation is encouraged! Features - The DXE-7580-THK consists of: Precision machined 6061 T6 Aluminum Hub Three Stainless Steel Hub Fastening Set Screws Seven Rod Fastening Stainless Steel Set Screws One 5/64" Allen Wrench Six pre cut 48" Stainless Steel Hot Rodz TM Six Plastic Safety Tips Custom "L" Bracket for mounting on the vertical antenna Two 1-1/4" Stainless Steel Studded Band Clamps and stainless steel hardware* * Additional Studded Band Clamps for a wide range of tube diameters and Hot Rodz TM of different lengths are available from DX Engineering for your specific needs. Tools Required Medium size flat blade screwdriver or 5/16" nut driver for the studded element clamps Tape measure Manual Updates Every effort is made to supply the latest manual revision with each product. Occasionally a manual will be updated between the time your DX Engineering product is shipped and when you receive it. Please check the DX Engineering web site ( for the latest revision manual

3 Capacity Hat Assembly and Installation Parts Listing: DXE-7580-THK Capacity Hat QTY Description 1 Smooth Hub 1 0.5" Mast Tube Connector Fitting 7 #8-32 x 1/8" long Stainless Steel Allen Screw - Cup Point (6 are used, one is a spare) 3 #8-32 x 1/4" long Stainless Steel Allen Screw - Flat Point (2 are used, one is a spare) 6 Hot Rodz TM -.125" x 48" Stainless Steel 6 Plastic End Cap,.110" x 1" long 2 Stainless Steel Studded Element Clamp, 1-1/4" 2 #10 Stainless Steel Star Washer 2 #10 Stainless Steel Flat Washer 2 #10 Stainless Steel Split Lock Washer 2 #10-24 Stainless Steel Nut 1 3/8" Stainless Steel Flat Washer 1 3/8" Stainless Steel Split Lock Washer 1 3/8-24 Stainless Steel Hex Nut 1 Top Hat 'L' Bracket 1 5/64" Allen Wrench Note: UMI Never-Seez or DXE-NSBT8 Anti-Seize should be used on all clamps, bolts and stainless steel threaded hardware to prevent galling and to ensure proper tightening

4 The drawing to the right shows the Capacity Hat parts for reference. Also included in this kit is one 5/64" Allen Wrench and one spare 1/8" and one spare 1/4" long stainless steel Allen Screws. 1. Locate the two 1-1/4" studded element clamps, the Top Hat "L" Bracket, two #10 stainless steel star washers, two #10 stainless steel split washers, two #10 stainless steel washers and two #10 stainless steel hex nuts. Assemble the studded element clamps to the "L" bracket as shown below. 2. Locate the Mast Tube Connector Fitting, one 3/8" stainless steel flat washer, one 3/8" stainless steel split lock washer, and one 3/8-24 stainless steel hex nut. Assemble the mast tube connector fitting to the "L" bracket as shown below

5 3. Lower the antenna and install the "L" bracket to the 1.125" OD element, just above the 1.25" OD element. Tighten the studded element clamps to hold the assembly in place. When mounted to either the DXE-8040VA-1 80/40 Meter Multi-band or the DXE-7580VA-1 75/80 Meter Monoband high performance Thunderbolt TM vertical antenna systems, the capacity hat is located as shown

6 4. Locate the Smooth Hub and two #8-32 x 1/4" long Stainless Steel Screw - Cup Point Allen screws. Using the supplied 5/64" Allen Wrench screw the 1/4" long Allen screws in the smooth hub in the two places as shown below. Only put these Allen Screws in half way, they will be tightened in a later step. These are the two Allen screws that hold the smooth hub to the 1/2" mast tube connector fitting. 5. Locate the six smaller Allen screws (1/8" long) and install them loosely in the smooth hub as shown below. These are the Allen Screws that will hold the Hot Rodz TM in place after you adjust their lengths. Insert the Hot Rodz TM in the smooth hub as shown below. Slide them in the smooth hub and adjust their length to be 3 feet. Tighten the appropriate Allen screw to hold them in place. Refer to the pictures below for reference

7 6. Install the Smooth Hub with the Hot Rodz TM on the 1/2" Mast Tube Connector Fitting. Rotate the smooth hub to position the Hot Rodz TM so they are not touching the vertical antenna element. Lock the smooth hub in place by tightening the two long Allen screws that were installed in Step Locate and install the six plastic end caps on the ends of the Hot Rodz TM. Tuning Adjust the physical position of the Top Hat on the 1.125" element tube section to achieve resonance on your target frequency. Sliding the Top Hat higher will shift the point of resonance to a lower frequency. The position of the Top Hat Kit rods within the hub will also affect tuning. Shortening the rods or removing some of them will shift the resonant frequency higher. The Hub with the attached Hot Rodz TM may be removed from the Mast Tube Connector Fitting leaving the Capacity Hat Bracket and Studded Element Clamps in place on the antenna

8 Optional Items Hot Rodz, 48 in. Stainless Steel Rods One set of six (in the lengths listed below) stainless steel rods, and plastic safety tips. Six Stainless Steel rods Twelve Plastic safety tips For use with the Hot Rodz Capacity Hat DXE-RODZ-48P DXE-RODZ-36P DXE-RODZ-60P DXE-RODZ-72P Hot Rodz, 48 in. Stainless Steel Rods Hot Rodz, 36 in. Stainless Steel Rods Hot Rodz, 60 in. Stainless Steel Rods Hot Rodz, 72 in. Stainless Steel Rods Band Clamp with Stud,.500 in OD tube, pkg. of 2 These clamps are great for mounting items or making connections to a tube or pipe with an outside diameters of 0.500" to 2.250". Each stainless steel element clamp has a 3/4 inch long, stud welded to it, which allows attachments without drilling holes that could weaken element or tower tubing. Stainless steel attachment hardware consisting of flat and split-ring lock washers and nuts are included. Sold as a package of two. Technical Support DXE-ECLS-050 Studded Band Clamp " OD tube - Package of 2 DXE-ECLS-062 Studded Band Clamp " OD tube - Package of 2 DXE-ECLS-075 Studded Band Clamp " OD tube - Package of 2 DXE-ECLS-087 Studded Band Clamp " OD tube - Package of 2 DXE-ECLS-100 Studded Band Clamp " OD tube - Package of 2 DXE-ECLS-1125 Studded Band Clamp " OD tube - Package of 2 DXE-ECLS-125 Studded Band Clamp " OD tube - Package of 2 DXE-ECLS-150 Studded Band Clamp " OD tube - Package of 2 DXE-ECLS-175 Studded Band Clamp " OD tube - Package of 2 DXE-ECLS-200 Studded Band Clamp " OD tube - Package of 2 DXE-ECLS-225 Studded Band Clamp " OD tube - Package of 2 If you have questions about this product, or if you experience difficulties during the installation, contact DX Engineering at (330) You can also us at: DXEngineering@DXEngineering.com For best service, please take a few minutes to review this manual before you call. Warranty All products manufactured by DX Engineering are warranted to be free from defects in material and workmanship for a period of one (1) year from date of shipment. DX Engineering s sole obligation under these warranties shall be to issue credit, repair or replace any item or part thereof which is proved to be other than as warranted; no allowance shall be made for any labor charges of Buyer for replacement of parts, adjustment or repairs, or any other work, unless such charges are authorized in advance by DX Engineering. If DX Engineering s products are claimed to be defective in material or workmanship, DX Engineering shall, upon prompt notice thereof, issue shipping instructions for return to DX Engineering (transportation-charges prepaid by Buyer). Every such claim for breach of these warranties shall be deemed to be waived by Buyer unless made in writing. The above warranties shall not extend to any products or parts thereof which have been subjected to any misuse or neglect, damaged by accident, rendered defective by reason of improper installation, damaged from severe weather including floods, or abnormal environmental conditions such as prolonged exposure to corrosives or power surges, or by the performance of repairs or alterations outside of our plant, and shall not apply to any goods or parts thereof furnished by Buyer or acquired from others at Buyer s specifications. In addition, DX Engineering s warranties do not extend to other equipment and parts manufactured by others except to the extent of the original manufacturer s warranty to DX Engineering. The obligations under the foregoing warranties are limited to the precise terms thereof. These warranties provide exclusive remedies, expressly in lieu of all other remedies including claims for special or consequential damages. SELLER NEITHER MAKES NOR ASSUMES ANY OTHER WARRANTY WHATSOEVER, WHETHER EXPRESS, STATUTORY, OR IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY AND FITNESS, AND NO PERSON IS AUTHORIZED TO ASSUME FOR DX ENGINEERING ANY OBLIGATION OR LIABILITY NOT STRICTLY IN ACCORDANCE WITH THE FOREGOING. DX Engineering 2012 DX Engineering, DXE, Hot Rodz, Maxi-Core, THUNDERBOLT, Antenna Designer, Yagi Mechanical, and Gorilla Grip Stainless Steel Boom Clamps, are trademarks of PDS Electronics, Inc. No license to use or reproduce any of these trademarks or other trademarks is given or implied. All other brands and product names are the trademarks of their respective owners. Specifications subject to change without notice