Step 1: Exploded View
Step 2: Sony ICF-S22
Tuner, speaker were extended in order to reach their required place in the radio.
A new battery pack was added to house 2 AA batteries.
The volume, on/off switch was extended and the on/off part was connected to a toggle switch.
Speaker was extended to fit design.
New battery pack was added.
The main circuit was kept attached to the face of the dictaphone because it is simpler to simply extend the buttons rather than make and attach new ones.
Step 3: Cutting Materials
I used a laser cutter when I made the radio, however they parts could be cut by saw if you are careful enough.
The plastic must be 5mm thick and once cut, using a sander with a 45degree angle sanded down around the edges in order for the parts to fit flush together. Note, for certain angles like the corners of the triangle that are not 45degree you have to leave them untill the gluing stage to correct.
All holes for inserts and buttons must be cut at this point to save unneeded hassle later on
Refer to the diagram for the sizes of the model.
Step 4: Assemble
I suggest making a 90degree angle to put the parts against whilst gluing.
I suggest a strong fast bonding super glue.
You will figure out your preferred order to attach the parts together but I started with the biggest base of each, followed by both sides, the sides then panels and inserts.
While the radio and recorder are taking shape you will find corners of the panels will stick out, these need to be sanded flush to the surface of the radio.
Remember to leave the back panel on the radio and right panel on the recorder of to allow access.
Step 5: Electronics
the main body of the Dictaphone is glued to the under side of the front surface, in line with the button and screen holes.
the speaker is glued over the speaker holes where you have chosen to place them.
the battery pack is placed in between the circuit board and speaker but is not attached as it has to be removed.
the speaker is glued behind the speaker cover.
the tuner and volume control must be glued into their fittings(these may differ depending on the radio you use).
the circuit board and battery pack are placed inside.
if your tuner is similar to mine you will need to unsolder and resolder it as shown in picks.
This will all be quite a tight fit but trust me it does.
Step 6: Finishing Off
It is easiest to glue your new twist knobs to the original internal cogs for strength.
To keep the panels on use magnets, this way they can later be removed to change then batteries.