You also need to download and print out the parabolic template located at Binary Wolf. I placed my craft aluminum lengthwise and parallel on top of a wooden rolling pin. Using the palms of my hands, I gently applied pressure to the aluminum and rolled it back and forth on top of the rolling pin until it began to have the right curve.
I matched the curve of the aluminum to the template I had printed out until it lined up correctly. Next I took my two pieces of plexiglass about 4 inches wide and cut them close to the desired shape, then using a sander I carefully sanded them down until they both met the parabolic curve. Next I drilled a hole for the antenna, the hole in one piece of plexiglass larger than the one in the other, because the WiFi antenna is narrower at the top than it is at the bottom.
Once all the pieces are ready you need an adhesive that will glue the plexiglass to the aluminum. Threw his brick wall to his router. Step 1: Calculations The first thing you are going to want to do is understand somewhat how a parabolic dish works. You can do a bunch of Googleing and reading and still not understand the mathematics behind wave angle, Illumination angles, etc. Lucky for the not so math savvy some people smatter then me have done all the hard work in a multitude or simple programs.
For my dish I have decided to go with 68cm diameter and a depth of 18cm. I recommend you use metric CM to do all your measuring as it is easy to figure the lengths with the program. Naturally in this case the bigger the better.
A larger dish will collect more of a signal. So if you feel frogy go right on ahead and make yours 6 foot. Input your Diameter and Depth into Parabola Calculator and hit calculate.
It will draw with default setting a dish in blue and the focal length in red. Notice that when to hover your mouse over the black area you get a cross and some numbers X and Y will appear at the bottom of the window.
The numbers indicate the distance from the deepest part of the dish center out to the edge X and how deep they are Y. Step 2: Layout Taking the calculations from Step 1 you will want to lay out the curve of the dish on a flat surface. Accuracy is important but you can be off slightly and still have an operational dish.
First measure your width diameter and find the center point. Now go to Parabola note a point X, Y on one side of the dish. Then measure the bottom edge from the center out to one side. Then measure the height up from that point. To assure you are not off to an angle use a T square if you do not have a T Square you can measure the depth again from the center of the dish Up and then from there the distance to the side.
Repeat this process on the opposite side. Then do it again more times at different points on each side marking each point with a dot or X. Connect the dots and you should end up with a curve like the one in Parabola. Step 3: Bending Supports and forming the dish base Now that you have your template made. Use something that is rigid but bendable to make 4 rods. Find the Center of the rod and chop it in half. I recommend bending the rod 1st because bending and forming a longer rod is easier than a short one.
Then use an octagon shaped piece of wood and drill holes in the side at the 12, , 3, , 6, , 9, and positions. Drill holes in the side of the octagon about 2 inches deep. Add some Super Glue and a little electrical tape to shore it up. Be sure to check your curves again just in case you bent it up a little.
Step 4: Feed horn and back Reflector Now we are going to work on the feed horn. This is the part the sticks straight out of the center of the dish that your USB device or router antenna will be fitted on. Once the signal is reflected by the dish it will concentrate a point called the focal. This is the spot in the dish that will have the strongest concentration of signal. At this point you could just it mount up and be done with this step. Personally I like to get all I can so I am going to make a 2nd mini dish to reflect any signal loss due to miss adjustment or placement of the receiver.
Preheat the oven to and place a CD on top of a curved lid or glass condiment dish. Place them in the oven. It should only take a few minutes to soften the plastic. You are shooting for a circle about 10cm 4 inches round and cm deep.
Take note CDs are made to take some heat and not bend. Bending it too far will cause breakage or deformation.
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