Chevrolet Venture and Pontiac Montana
Heavy Duty HF Antenna Mount
The following page describes an antenna mount for a Chevrolet Venture or Pontiac Montana. It can handle an 8 foot whip or hamstick antenna easily. This method can be extended to other cars, minivans and SUVs of similar design. I made the mount for two antennas, but you can modify it for one antenna.
The finished product looks like this:
Now to get into the details:
You will need the following materials:
Aluminum sheet: 12x12 Inch piece of 0.250 inch thick
Aluminum Angle: 6 Inch Long 3/4 x 3/4
Stainless Steel screws and nuts: QTY 6, 1/4 inch Diameter x 3/4 inch long
Aluminum Stock: Approx: .020 Inch Thick, 6 Inch Long x 1 Inch wide
You will need the following tools:
- 1/2 Inch diameter drill press & 1/2 Inch Dia Drill Bit
- Hand Drill & 1/4 Inch Diameter Drill bit
- Jigsaw with metal cutting blades
- Hacksaw with metal cutting blade
- Sander with medium grit paper
- Metal file
- 5 Minute Epoxy Glue
- Silicone Adhesive
- Torx Screwdriver bits (to remove tail light)
- Bench vice and holding clamps
Procedure (This will take a good 3-4 hours)
- Print out the templates Template 1, Template 2
- Trace the outline of the template 1 and cut a cardboard outline.
- Remove the stop/tail light & disconnect the wires.
- Push the wire harness boot into the body, and route the wires into the body. Pull the wires out of the tire jack compartment so they are out of the way when you drill the holes.
Picture 47
- Place the template on the van as shown. Note any adjustments to the template (adjust the radius to the way you want it for a better fit.
Picture 50
- Trace, cut and fit the template in the final position.
- Trace the template outline on the aluminum sheet.
- Cut out the shape of the aluminum sheet. This is the hardest part of the whole process and takes about 1 to 1.5 hours. I used a hacksaw to start and a jigsaw for the final shaping. Deburr (round off) the sharp corners with a metal file. Sand the edges and the surface of the plate to obtain an even consistent finish.
Picture 49
- Measure and cut a piece of the aluminum angle with the hacksaw and round off the corners with the file.
Picture 58
- Mount the aluminum plate and the angle into position and mark the position of the angle onto the aluminum plate with a pencil.
Picture 49
- Mark-off 6 mounting holes in the aluminum angle and drill 1/4 inch holes using a drill press.
- Position the angle onto the plate in the position you marked off in step 10. Mark-off the holes in the plate and drill QTY 3, 1/4 inch dia holes.
Picture 49
- At this point adjust the design to whatever antenna mount design you have (i.e Ball Mount etc).
- Mark-off the hole for the 3/8-24 antenna mount (or the mount you have). I made the mount for 2 antennas; one for an 8 foot whip and the other for a loaded antenna.
- Drill a hole in the plate to accept the insulated antenna mount-usually 1/2 inch.
- Adjust the design to accept whatever antenna mount you have.
- Secure the angle to the plate using 1/4 inch stainless steel screws.
Picture 49
- Mount the plate/angle into position and mark off the 3 holes on the van. I added a fourth hole for a ground braid.
Picture 60
- The left over angle will become a backing plate, so drill 3 matching holes in it and cut off the L-portion of the angle so that it is a flat plate.
Picture 59
- Drill QTY 4, 1/4 inch holes in the van.
- Remove the paint around the van mounting holes by lightly sanding to bare metal.
- Cut a 1/2 inch strip of thin aluminum sheet and epoxy to the rear of the backing plate.
Picture 59
- Bend the strip so that you can easily mount the backing plate into position.
- Install 3 stainless steel screws onto the backing plate such that the threads face you. Use electrical tape to keep the screws from falling out.
Picture 59
- Carefully mount the backing plate into position inside the taillight recess, and ensure the screws protrude.
- Secure the ground braid to the aluminum plate.
- Apply silicone adhesive on the top of the plastic body molding where the plate will sit.
Picture 59
- Mount the plate and secure the nuts onto the screws.
- Mount the insulated 3/8-24 antenna mount and route the coax through the rubber tail light grommet and into the passenger compartment.
- Apply silicone adhesive to seal the metal to metal joint & screws.
- Re-install the taillight, mount your antenna and you are done!!
Picture 63
Now all you have to do is tune the antenna
Have Fun!!
