Step 2: Hacking the radio chip

Hacking the radio chip requires extending the wiring of the components. Firstly, de-solder the 6 connection points for the tuner. Solder some 120mm wire in place. I found that the extra wiring acts as an ariel, and interferes with the signal, wrapping these wires in tin foil seems to correct this problem. Then, de-solder the 3 volume connectors and solder in 3 new pieces of 120mm wire. Finally, de-solder the battery connectors, and add in a new AA battery case.
<p>what do u mean by &quot;120mm&quot; cause i used that length and the fm still doesn't work</p>
Well, it looks like a perfectly good and strong plastic case has been replaced by a thin cardboard case. I like the flatpack idea but plastic radios already come pre-packaged in boxes. So the packing of little boxes inside a larger box is not really any issue.<br><br>I guess very hot and dry climates would be good for such a radio if the plastic were to be endangered by the environment. I'd avoid sending a cardboard radio case to any place with humidity and rain though. <br><br>Something to consider for a future design which would be cheaper in a developing country would be to design a fully screen printed radio circuit which has no 3-D components. I don't know if we can screen print all different kinds of electronic components yet, but that would allow for a cardboard radio. (It's rumored that in Japan some cellphones were once printed onto the cardboard of cereal boxes. It was a sales gimmick to get people to sign up for cellphone service on a contract.) Maybe someone can veryify or debunk this....<br>
I'm pretty sure that if such a thing were done for promotional use, they would use Surface Mount Devices (SMDs). The circuitboard can be made thin, the components are only 1/32&quot; high (maybe 5/64&quot; for electrolytic capacitors. With digital tuning, you don't have the coil arrays or variable tuning capacitors. You couldn't get the thing to work just printed on cardboard, but you could connect a flexible PC board (high-temperature ribbon cable looking thing) to the cardboard with glue. Definately doable, but unwieldly to use comfortably.
I know comments are expected to be positive, constructive, but there are those times, when one runs across an instructable that no matter how well intend goes in the wrong direction. First determine the broadcasts bands in the country of interest, and send the the purchased radio as is. In light as another pointed out batteries are a liability. The freeplayenergy radios would be the ones to donate. Particularly the 4 band model, if it's sill available.
Great to developing countries... so they should buy a new one every few months... why always people relate &quot;useless trash&quot; with &quot;hey... send it to developing countries... we're such good people!!!&quot;
neat design but if this is gonna go to a third world country regular batteries are not the way to go
very nice simple design. What are your estimated costs for manufacturing this.?<br>great project.!

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