Materials you will need:
- average consumer radio (I used the Sony ICF-S22)
- 2m of felt (colour of your choice)
- 30cm square or felt (different colour to above)
- 2m polyester padding
- 9 red LEDs
- 2 small speakers
- 3 large buttons of your choice
- 2 snap fasteners
Tools you will need:
- soldering iron
- sewing machine and dress pins
- needle and thread
Step 1: Dismantle a Radio and Extend Wires
Once I had come up with the design I began extending wires where needed. I took the existing speaker off and attached 2 slightly smaller speakers in parallel. This worked fine for me with out losing power in the speakers but if you are using a different radio or speakers I would check at this point to make sure they will work.
I connected 9 red LEDs in parallel and wired them into where the tuning indicator LED had been. I did this so the scarf would light up when it is in tune. Its not essential but does look great.
I wanted the radio to be turned on by an interaction with the scarf. I decided to put buttons running up the front and to turn the radio on you need to do up one of them. For this I extended the batteries so they would be on the opposite end of the scarf to the circuit board. One wire runs along the scarf to the battery cell and another goes to the button. A wire also comes from the battery cell to the associated button hole so that when this button is done up the circuit is completed. It sounds more complex than it is.
The other 2 buttons on the front of the scarf are for the volume and tuning. They don't need extending as the circuit board goes directly underneath the other buttons.
Step 2: Cut Out Material and Padding
I made the scarf 25cm wide. This I regret with this specific material. The felt and padding combo makes it too stiff and chunky for how wide it is. I would have gone for 20cm maybe 15cm wide if I was to make another. If you are using a floppy material you should be ok.
Whatever width or length you go for make the paddy 1or2 cm less as when you are folding the felt over to make hems you don;t want them getting too chunky with padding inside them.
Step 3: Sew Poaches for Battery Cell and Circuit Board
Step 4: Lay Out Wires on Material
Put a layer of padding over the wires and remove any pins that are still in place. Then you are ready to put your second/top layer of felt down. Pin around the edges, tucking the cut edge into the inside of the scarf. Leave ends open and battery wire exposed so you can find it later.
Step 5: Sew Scarf Edges
Step 6: Cut and Sew Holes for LEDs and Speakers
I located each LED by running my hand over the scarf to feel them underneath the felt. After locating the LED I took a small pair of scissors and cut a hole through both the felt and padding. CAREFUL not to cut any wires hidden inside! I poked the LED through the hole and used a needle and thread to tighten the hole around the LED. I made sure I went under the wires of the LED so I was effectively sewing the LED to the outside of the scarf. I also put stitches from one side of the LED under it to the other so the LED was forced against the outside layer of felt when the stitch was tightened.
For the speakers. Locate the speaker and cut a hole for it to fit through. This should be accurately sized and circular. Cover the speaker with a square of your second colour of felt. I sewed it in similarly to the LED. This is very fiddly. Try to keep your stitches tight so the speaker doesn't wriggle out.
Step 7: Cut Holes for Buttons and Glue/wire Them On
Firstly, locate your tuner and volume control on your circuit board through the felt. Once you've found them, cut holes to expose them through the felt and padding. This hole doesn't have to be tiny, as long as your button is a bit larger than the hole it should be fine.
Now, I came across a problem at this stage. The padding and felt was too thick for my buttons to be glued on to the circuit board directly so... I used 2 smaller buttons glued one on top of each other as extenders. This does actually work well but if I had known before I would maybe have used a small piece of wood or similar. Prepare your Araldite carefully following its instructions. Apply to all 3 buttons and leave for... a while until it has set a bit. It doesn't have to be completely set for the next stage just don't do this next bit when the joins are still super fresh.
Apply a small drop of Araldite on to the component, be careful to only touch the part of the component that moves. Put a small drop of Araldite on the back of the button construction and press down on to component. Hold in place for up to ten minutes to make sure its held. Repeat for other component.
Cut a hole at an even space to the other buttons and tease the wire out. Get some spare wire and take off the plastic exterior and weave it through the 3rd button. Twist this into the exposed wire and Araldite the button in place or sew it into the hole so it doesn't come out.
Step 8: Create Button Holes
Step 9: Sew the Ends of the Scarf
Step 10: WELL DONE! You Have Finished
If you have any questions or comments, please do not hesitate to contact me.