Articulo: Hacking a Radio For Tradesmen and Outdoor Labour

Step 3:

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To construct the curved end pieces of the radio casing you must first turn the high density foam (or other) to a cylinder of diameter 100mm.  From here start to work the cylinder into the curved shape shown, aim to work the curve until a diameter of 50mm is reached at the end of the mould.  Once you are happy with the rough form, go over the rough turned shape with various grades of sandpaper to remove any irregularities and achieve a smooth and even finish suitable for vacuum forming.  Next cut to a length of 70mm, giving the shape below.
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