I've got some ideas on how to solve for this.. But I was curious what you guys would recommend.
I have an aluminum radar arch
and I originally had a (very heavy) open array radar
on it. Today I removed the Raytheon
and attempted to install a new radar mast
for updated radar electronics
The bolt pattern on the radar mast
doesn't match the old radar bolt pattern. Of course not, why would anything be simple?
I can't drill new holes in the aluminum
arch plate because the radar mast bolt pattern perfectly overlaps some welds for the arch bottom cover. On all 4 corners. Just not an option.
I think it's important that the weight of the new radar mast is balanced well so the arch isn't under extra stress. So shifting the mast forward for clearance (while simple ) isn't a good option either.
So there's the problem. I have two metal plates with different bolt patterns that must be joined.
My idea is to fabricate an adapter plate thick enough to nest the bolts for the radar mast inside. So 3" thick or so (3 layers of plywood). Then coat it in resin to seal.
But having wood
sandwiched in between two metal surfaces sounds like a bad idea. The compression
, the wear, weather
, ice, etc is just going to be really hard on the relatively soft wood
. But I'll give it a shot.
I'm not planning to use fiberglass
. It will probably be prone to cracking once I torque the assembly down.
Any simpler solutions I haven't thought of yet?