Step 1: Taking Apart Sony Radio ICF-S22
Step 2: Exploded Diagram
x1 1000mm x 1000mm x 12mm (This should be a sufficient amount of MDF for the whole model)
x1 Tub Of Wood Filler
x1 Sony ICF-S22 Radio ( or any other small portable radio)
x1 Beats by Dr Dre Studio Headphones
x1 Push Switch
x1 Removable Battery Pack
x1 15mm dowel
x1 PVA glue
x1 Band Saw
x1 Hand Sander (or just a bit of sand paper)
x1 Wood Filler
x1 Primer Spray Paint
x1 White Spray Paint
x1 Soldering Iron
x1 Wrap of Multicord Wire
x1 Wrap of Solder
Step 3: Changing Circuit Board
Step 4: Starting Prototype ( Headphone Stand)
Step 5: Cutting Headphone Stand
You will need to get two more layers of 12mm MDF and glue them together, you will need to do this twice for both sides of the headphones stand. Any size will do because you will be cutting them to size with the plainer. You will need to take these two bits of MDF and clamp them to each side of the headphone stand. Then you will need to again draw the profile of the headphone ear parts.
Once you have done this you will have a very rough edge and you will need to sand this down with a belt sander or a bit of normal sand paper. If you do this correctly you will get a very nice finish.
Step 6: Gluing Side Pods to Main Body
There is a very sharp edge where the two side part meet the main body. To make this a softer edge you will need to use your wood filler and mold it to the edge. Then you need yo wet your finger and slide it along so it curves. Once you have done this leave the wood filler to dry.
Once the wood filler had dried you will need to sand it down to give it a nice finish. Wrap the sand paper round a piece of dowel and this will give you the finish you need.
Step 7: Handle
You will need to take your the main headphone stand and draw the profile of the curve on the MDF. Once you have done this use a band saw to cut the shape out. The shape will be very rough so you will need sand it down with a piece of sand paper.
Next you will need to drill the holes for the handle. You will need a drill bit that is size 28mm to do this. From edge to edge of the holes it measures 94mm.
You will need to then use the plainer again to make a curve for the handle. You need to draw the curve on free hand or use an elipse to draw it. As before with the curve on the headphone stand you need to plain it and then use the hand sander and sand paper to give it a softer edge.
The circuit board must be placed inside the radio so you will need to use a milling machine and mill out a casing in the middle. It should be 25mm deep and measure the width of the circuit board and the battery pack combined. You will also need to mill out a small casing for the lid. This is 2mm all around bigger then the size you have milled for the circuit board.
The headphone jack will need a small space in the front of the handle. Use a small drill bit of 10mm to make this whole.
Step 8: On/Off Button
To make the button is very simple. You only need a small bit of MDF that measures 32x25. Once you have this shape you will need to sand the edges so that it fits to the hole.
Step 9: Drilling Holes for Wires and Making Lid.
Making the lid is very simple as well. It is a small piece of MDF that is 2mm thick. It measures 95mm by 105mm. It need to be curved in one corner so you can pull it off to change the batteries. you should place it on the handle and sand it to compensate for the curve of the handle.
Step 10: Final Assemlby
Once this is finished you will need to feed your wires through the hold at the top and through to the handle. This is very tricky you will need to patience to do this. When you have done this you can assemble them all together.
To make the knobs again use some 12mm thick MDF and cut them to shape. You can use any size of circle you want as long as they don't overlap each other. Then you must take two bits of dowel and attach them to the circuit and cut holes the size of the dowel into the lid. Then glue the dowel to the circuit and the knobs.
When you have assembled everything you will then need to spray paint it. Use 3-4 coats of primer and then use 2 coats of white spray paint. Once you paint has dried you should have the finished product.