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Building guide / Bakvind weather station mast

A simple mast built from standard parts.

We at Bakvind have built our own weather station mast and share the design as inspiration for others. There are many good ways to build a mast. The essential requirement is a 25 mm diameter tube for mounting the weather sensor.

This is our solution, not the only correct one. Adapt the materials, height and anchoring to the site where the mast will be installed.

Weather sensor mounted on a mast tube

The construction

Two tubes with different purposes.

Our mast is based on parts from Biltema, a large automotive-accessory chain in Scandinavia. If you live elsewhere, use the ideas as a starting point and find equivalent parts locally.

The lower and longer section is a galvanised steel tube sold as an antenna mast section. It is strong and makes it easy to attach guy wires, the radio node and other equipment. The tube has flanged ends and can be joined to an additional section if a taller mast is required. The short upper section is a 25 mm diameter aluminium tube that fits directly into the weather sensor mount.

Between the tubes we use a 3D-printed adapter that is tapped into place. The adapter can also be secured with a screw. Another option is to adapt the tubes so they can be screwed directly together without an adapter.

Solar Node mounted on a mast tube with pipe clamps and drilled holes for guy attachment points
The galvanised mast tube carries the guy wires and equipment. A short 25 mm aluminium tube at the top fits the sensor.

Galvanised steel tube below

The strong main section provides mounting points for guy wires and equipment and withstands more load than the upper tube.

25 mm aluminium tube above

The short upper section fits the WS90 sensor directly. Keep it short because the aluminium tube is less robust than the steel tube.

Guying on rock or soil.

Three M6 eye bolts with nuts serve as guy attachment points through the mast tube. For installation on rock, steel wire runs from the eye bolts to three anchors made from M8 expansion bolts and eye nuts in the rock.

In soil or other soft ground, Biltema’s ground anchor can be fitted directly to the mast tube. We also recommend guying it with ordinary tent guy ropes and pegs.

Biltema M6 x 69 mm eye bolt with nut, used as a guy attachment through the mast tube
Three M6 eye bolts are fitted through the mast tube as guy attachment points.

01 / In the workshop

Prepare the mast.

The mast tube and aluminium tube are common to both installation methods. Prepare the holes you need before taking the mast to the site.

  1. Position the mast tube with the narrow end down and the wide end up.
  2. 3D-print the adapter between the mast tube and aluminium tube from the STL file below.
  3. Fit the aluminium tube into the top of the mast tube. The 25 mm aluminium tube fits the weather sensor.
  4. If using guy ropes or wires, 3D-print the drilling jig, drill three holes and fit the M6 eye bolts through the mast tube with nuts. This is required for rock installation but optional when using a ground anchor.
  5. Mount the Solar Node on the mast with two pipe clamps or hose clamps as described below. You can also use another Bakvind node or place the node elsewhere.
  6. For rock installation, position the angle bracket against the mast tube and drill an 8 mm hole near the bottom of the tube, aligned with the height of the bracket.

Mount the Solar Node without the tilt mechanism.

The supplied bracket does not fit the mast tube directly. We remove the part intended to mount against the mast and do not install the tilt mechanism. Clamp the main bracket directly to the mast tube with two pipe clamps or hose clamps. If the solar panel needs a different angle, bend the main bracket to the required angle.

In the Northern Hemisphere, the solar panel should face south. Set the angle so the panel receives good sunlight throughout the year, paying particular attention to the lower sun in spring and autumn at northern latitudes. Avoid shade from the mast, sensor and vegetation.

The node is normally mounted on the same mast as the sensor. The expected Bluetooth range is up to 30 metres, so other placements are also possible.

Consider painting the mast matt black before installation. This prevents the shiny surface from reflecting sunlight and makes the mast less conspicuous in the landscape.

Solar Node mounted on a mast tube with pipe clamps and drilled holes for guy attachment points
Solar Node attached with pipe clamps. The holes in the mast are for guy attachment points. Select the image for a larger view.

3D-print a sleeve that keeps the antenna upright.

The Seeed Studio Solar Node antenna has a joint that allows its angle to be changed. We have made a 3D-printed sleeve that slides over the joint and keeps the antenna upright when the node is mounted on the mast.

Download the antenna-sleeve STL
Seeed Studio Solar Node antenna beside the 3D-printed sleeve that keeps the angle joint straight
The sleeve slides over the antenna angle joint so the antenna stays upright.

3D-print the adapter between the tubes.

The adapter joins the galvanised steel tube sold as an antenna mast section to the 25 mm diameter aluminium tube. Print it from the STL file and tap it into place between the tubes. The adapter can also be secured with a screw.

Download the adapter STL
3D model of the adapter between the galvanised mast tube and 25 mm aluminium tube
The adapter joins the galvanised mast tube to the 25 mm aluminium tube.

3D-print the drilling jig for the guy attachment points.

Slide the drilling jig over the mast tube and use it to mark and drill the holes for the three M6 eye bolts. It provides the correct angle and spacing between the guy attachment points.

Download the drilling-jig STL
3D model of the drilling jig for three guy attachment points on the mast tube
The drilling jig positions the three holes at the correct angle and spacing.

02 / At the site

Same mast. Different anchoring.

Choose the method that suits the ground conditions. The rock version uses guy wires. For installation in soil, assess the need for guy ropes based on location and stability.

Installation in soil

  1. Drive the ground anchor into the soil.
  2. Bolt the mast to the ground anchor once the anchor is in place.
  3. If using guy ropes, drive three pegs into the ground, evenly spaced at 120-degree intervals around the mast.
  4. Attach guy ropes between the attachment points on the mast and the pegs in the ground.

Installation on rock

  1. Drill a hole for the expansion bolt where the mast will stand.
  2. Pass an M8 bolt through the drilled hole and the angle bracket, then secure it with a nut.
  3. Drill holes for three expansion bolts, evenly spaced at 120-degree intervals around the mast.
  4. Install the expansion bolts with eye nuts.
  5. Fit wire ropes with clamps between the attachment points on the mast and the ground or rock anchors.
  6. The third wire can be tensioned temporarily with a ratchet strap until the wire rope clamp is secured.
Angle bracket mounted on an expansion bolt for rock installation
Lower rock mounting: the bracket is secured with an expansion bolt. Drill the bottom of the mast tube and attach it to the bracket with a through-bolt and nut.
Rock guy anchor with eye nut, expansion bolt, wire rope and clamp
Rock guy anchor: an eye nut on an expansion bolt, with wire rope and clamp. This mast setup uses three of these anchors.

03 / Final checks

Install the sensor and check the readings.

  1. After installing the mast, attach the sensor at the top. The cable should extend down into the tube.
  2. Align the sensor so its north reference points north. On this sensor, the battery cover with the shiny screw should face north. Use a compass for accurate alignment.
  3. Tighten the sensor mounting once it is correctly aligned.

Check that the mast and its attachments are secure and that fresh measurements appear on the correct station page. Check the wind direction after aligning the sensor, and plan inspections and maintenance.

Parts and accessories

Parts used in this setup.

Start with the common parts and add anchoring and guy ropes or wires for your site. Quantities refer to individual parts, except pipe clamps and guy ropes, which are listed in packs. Wire rope is listed in metres; adjust its length to suit the site.

Guy attachment points on the mast

Three M6 eye bolts are fitted through the mast tube with nuts. They are required whenever the mast uses guy ropes or wires, whether installed in soil or on rock. For the ground-anchor version they are optional, because the mast can also be used without guy ropes.

Optional guy ropes for soil installation

Add these to the ground-anchor version if using guy ropes. You will also need the guy attachment points on the mast.

The complete weather station

The mast is one part of the setup.

See Hardware to choose a sensor and node, or Get started for device setup and firmware installation.

See hardware →Get started →