ON-SITE FABRICATION OF ANTENNAS

Large parabolic reflectors are constructed on-site from raw materials supplied in a kit, wherein the reflector is formed on an inflatable mold having a convex surface with appropriate contour. Upon inflating the mold, which may be impregnated or initially sprayed with a releasing agent, a layer of ultraviolet-sensitized polyester gel-coat or polyester resin is spray-applied thereon. Following this a predetermined number of layers of fiberglass-reinforced polyester resin is sprayed-on. Internal reinforcement ribbing pieces (e.g. plywood), having apertures therein and at least one surface corresponding in shape to the mold surface, are then radially arranged on the mold and held in place by polyester resin-sprayed fiberglass attachment fillets. Polyurethane foam is then applied, embedding and foaming in place the reinforcement pieces and also sectional pieces arranged piece by piece in concentric circles on the mold surface, with the apertures therein providing continuity between sections of cast polyurethane foam. Following this, a second laminate layer of fiberglass-reinforced polyester resin is sprayed-on. The mold is then deflated and a reflecting agent (e.g. aluminum) is sprayed onto the reflecting surface.