MIL-HDBK-660B
3. DEFINITIONS. Not applicable.
4. GENERAL REQUIREMENTS (PREPARATION FOR BENDING AND TWISTING)
4.1 Fabrication of template. The first step in fabricating waveguide bends is to make a full-scale template (see figures 3 and 4). The purpose of the template is to provide the shop with accurate information as to the shape,
radius, and angle of all bends and twists in the waveguide as well as the position of the connection, flange holes, and overall length of the run.
4.1.1 Template materials. The template can be made of .5-inch mild steel, wire, plastic, or wood. If the template is made of wood, choose its size to approximate the size of the waveguide to be installed. The flange can be made with wood to the exact dimensions including hole spacings. By using a wood saw, hammer, nails, and woodscrews, the template could be made at its given location and returned to the shop for waveguide fabrication.
a. The advantages of using wooden templates include:
i. A rigid shape can be transported easier than a flexible one.
ii. Wood can be cut to approximate the dimensions of the waveguide. iii. Ease of marking wood to note proper clearance for bends.
b. The disadvantage in using wooden templates is that a gradual radius cannot be shown.
4.1.2 Conforming template shape. When the template is at the shop, it can be placed on a bench or table and one flange can be fastened securely to the table in the proper position. The waveguide bend to be fabricated can then be made up until it sets between these flanges and conforms to the shape of the template. For making a twist in a waveguide where no "H" or "E" bends are required, a template as shown in figure 5 can be used.
FIGURE 5. Template for waveguide twist.
4.2 Annealing. Annealing is always necessary if the waveguide is to be formed in any way. If the guide is filled with rosin or alloy, filling is performed after annealing.
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