Articulo is a new take on the traditional 'tradesman's radio', incorporating durability, functionality and aesthetics into one package. Through the use of a flexible middle section the device can be wrapped around, hooked on or otherwise attached, securely, to its surroundings. Simple twist controls operate the volume and station settings, these are easy to use and are less vulnerable to damage from build up of dirt. A large push button on the end of the device allows easy on/off. Articulo is made to last, employing a tough weatherproof outer casing to ensure it is as durable as it is functional.
Step 1: Materials List
- 300mm length of 100mm internal diameter white piping, 2-3mm thick.
- 700mm length of 50mm diameter aluminium semi rigid ducting.
- Large sheet of 2mm white styrene (exact amount will vary with different vacuum formers)
- 800mm2 of 9mm mdf,
- 200mm of 12mm diameter doweling
- 200mm of 8mm diameter hollow metal piping.
- 6 x ball bearings (internal diameter: 12mm, external diameter: 28mm, width: 8mm)
- Epoxy resin
- 44x 45 block of pine.
Step 2: Dismantling the Radio
To remove the mould you may need to drill a small hole in the end of the plastic (as seen below) to allow air between the two surfaces.
Once the mould is removed you are ready to cut the plastic shape to side. Trim as much excess plastic off with the plastic band saw as possible then sand flush and smooth with a high grade sand paper.
Step 5: End Caps
As the curved ends, these will slot snuggly onto the tubing.
Drill a 48mm diameter hole in one of the two cylinders for the speaker to be mounted to. The speaker can be mounted to the inside of the hole using epoxy resin.
Step 6: Cutting the Piping
You will need to cut the following lengths of pipe:
- 3 x 30mm sections
- 1 x 40mm section
- 1 x 130mm section
These lengths of piping will be slotted over a selection of wooden disks to form the basic structure of the casing.
Step 7: Central Axis
To create the cylinder, sand the corners of the piece of pine to create a cylinder of dimeter 44mm x 45mm. Using a pillar drill, drill a hole of dimeter 28mm all the way through and slot in the 4 bearings. Feed the two rods in, through the bearing at either end, adjusting accordingly should they touch in the middle.
Step 8: MDF Disks
Mark out the MDF with a total of 7 disks diameter 100mm. Use a band saw to cut out the rough shape of the disks then finish to size using a disk sander. The disks must be cut and sanded accurately in order to fit snuggly in the piping.
Now two pairs of the disks and glue them together to form two separate 100mm x 18mm disks. These thicker disks are the twist controls that will later be attached to the tuner and volume adjusters.
Once the disks are cut to size you can start drilling the holes to house the bearings and the central axis. In two of the 100 x 9mm disks, drill a 28mm hole in the centre to house the bearings. In the two 100 x 18mm disks first drill a 11mm hole for the rods, followed by a 48mm inset 8mm deep. This inset hole slots around the central axis without touching it, allowing the rods to move freely.
Step 9: Twist Control Diss
First drill a 12mm hole in the disk then thread it into a finely bladed band saw to cut out the arc. As these discs are totally concealed they can be cut by eye so long as the width remains above 12mm.
In the two thinner disks, drill an 8mm hole in line with the specially cut slit.
Step 10: Frame Assembly
Step 11: Flexible Middle
The tubing was cut to 700mm length and glued to the casing using epoxy resin.
Step 12: Electronics
First of all the volume adjuster and tuner must be carefully desoldered and removed from the circuit board. They must then be extended with roughly 1 meter of wire so they can run through the radio casing. Its worth taking the time to label all the the wires and positions that they came from as they cannot be re-soldered to the extended wires until all the cables have been fed through the length of the casing, so it virtually impossible to keep track of them all! The volume and tuning extensions must be run through the flexible tube and into the other end of the radio. From here, simply connect the volume dial directly onto the first of the rods, and run the tuning extension through the inside of the hollow support tube and connect it to the second rod.
The speaker must also be extended by 100mm or so, it can be glued to the pre-cut hole. Finally a new battery housing must be added and attached next to the circuit board.