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The Ski Radio is my Solution to a design brief for Product Design.

Attachable to Ski Goggles, the radio comprises of four vaccum formed shells, speakers and a Sony Radio.

Step 1: Dimensions

The design has not got much room for error. It is designed around the existing circuit board and suited to fit the borrowed speaker surrounds from a pair JVC headphones. This is my template, but suit yours to your Radio and Headphones.

Step 2: Clay

Build up Four shapes from the dimensions, large enough to house all the components.

Self Drying Clay works best as it doesn't crack as easily if still a little soft.

Sand each pair back to back to the shapes match. Smooth the form and add any extra detailing you choose.

Step 3: Vaccum Form

Using High Impact Polystyrene Sheeting (HIPS), Vaccum form the pieces, including space for the flat surfaces.

Step 4: Cut and Drill

Cut the shapes to size.

Either fine band-saw or dremel like cutting tool is recommended. Include speaker holes and again
remember the flat surface areas that are needed for the speaker sponges.

Step 5: Solder (Left)

This is the tricky part. Assemble circuitry.

This can be done by removing the existing battery components and jack port, placing the jack port to the outside ot the model. Although in the interests of aesthetics, I used a  jack splitter to simplify the soldering and leave a smarter jack port for the exterior. see 7.

The cross flex between left and right must be a four core durable standard copper wire; not single core. I recommend quality audio cable.

ctd on 6

Step 6: Solder (Right)

Wire the flex to the speaker and the Battery Pack

Step 7: Hot Glue / Fixings

Hot glue is the fastest assembly method. The control wheels are simply lego. For better control, Construct cogs from spare HIPS sheeting and cover with sandpaper.

Ajust the hight to fit the outer shell.

Secure the cross flex with appoxy resin or equivelent.

Step 8: Rubber Seal

Attach rubber sealing to the edge of one side or both of the casings.

The best I found was a pre-taped window and door insulation rubber.

This will seal the inards from the elements.

Step 9: Bolts

Using 10-15 mm dowel, estimate the depth between the inner and outer shells.

Sand it down until it is short enough to fit within the two.

Using a router, make an extrusion to fit a bolt into. I recomment a 5 MM galvanised nut and bolt, possibly from a mechano set.
This can now be glued into place allong with the bolt.
The hole can be located by magnet, compass or sticky paper on the bolt before closing. Drill the apposing hole in the outer shells and you can close your radio up.

Step 10: Clips

Clips are the most awkward. Allignment may depend on how you wair your Goggles. Also Many clips will work.
I opted for curtain hooks. Again using HIPS plastic strips, I joined them together and glued them. Then shorten the curtain hooks allowing space for the straps and located them thusly. 

Step 11: Locating Hooks, Finish and Aesthetics

Locate the hooks as low to the speaker sponge as possible, and the upper one as far back as is confortable.

Finish with a textured stone spray. Follow instructions and do many light coats to achive effect.
This is easily held in gloves and gives it a rugged look.

Use felt pads to add friction against the strap and provide support and comfort.

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This was produced as a working model only and requires development to see actual functionality in said envoronment

Step 12: Cadd Model

Cadd Model

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