Instructables
Picture of The Box Radio
Im in my 2nd year at University of Dundee studying Innovative Product Design, this semester i received a brief to design and build a radio casing. In this blog i will record how i built the final prototype radio including an exploded diagram, photos and any other relevant drawings or notes. I hope you enjoy it and have a go at making it yourself, any unclear detail please post and i will get back to you.
 
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Step 1: Cutting and parts list

Oak length, width, thickness and quantity
 - 180mm, 80mm, 14mm [ x2]
 - 80mm, 80mm, 14mm [ x2]
 - 231mm, 131, 12mm [ x2]
 - 80mm, 33mm, 33mm [ x4]

Pine dowel
 - 40mm, 26mm [ x2]

Radio circuit board and ariel [ x1]
 - spare wires
 - soldering iron



Step 2: Exploded view

Picture of Exploded view
Here is an Exploded view to help you see how all the parts will fit together. I have included a PDF because its quite difficult to read.

Step 3: Dismantling a radio

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We received this Sony radio to dismantle to use the circuit board in our radios however any radio can be dismantle but sizes can differ and you will have to size any holes etc to the correct sizing to your particular radio chip. I used precision screw drivers to take off the outer casing and get at the circuit board later i extended the different components to fit into the radio shell but until then keep it all in one piece.

Step 4: Building the radio body

First take your wood panels and use a router to route 7mm width and 12mm depth on each side of every piece (see pictures). Next take the four corner pieces and tape together flush and drill a 56mm hole in the very centre down 12mm on both sides, you now should have all 8 pieces ready to put together but next we need to cut the am/fm, headphone jack and ariel holes. Keep the 4 corner pieces taped together until gluing the box together and label their sides so you can tell which one goes where.
chipper351 year ago
Somehow, I missed how you made the corner braces.........can you point that out for me??
JonnyLawrence (author)  chipper351 year ago
Yeah it looks like i actually missed that step out. I made all four corners in one go; first i cut them to the correct length and then held them together with tape in a square shape ( 2 by 2 ) next i clamped them in to a drill with a circular drill tip, I can't remember the size now but i should match the curved corners of the front panel. Next you drill down the thickness of the front panel so it can lie flush with the corners, (some sanding will be required) I did this both sides whilst all four corners were taped together. When you remove the tape just letter/ number which side fits to wear this will make it an easier when putting them in place for the gluing stage. I hope that helps if you have any more questions or if its still unclear ill do my best to answer / explain. Thanks for taking a look :)
meddler2 years ago
I like this, gonna fave it.
JonnyLawrence (author)  meddler2 years ago
Thanks :)
electronfan2 years ago
I've just seen your project and it's just cool. Have you tought on changing that soo small sounding smallspeaker? You may find easily one going lower in frequency that fits there ;don't miss to add some acoustic isolating stuff ( I used old but clean socks ) . Also you can toy it connecting to a full size loudspeaker ; it may surprise you the quality of the sound ! Maybe not High End but fair at the end ; I used to doy that with an old radiorecorder and got a fair sound.
JonnyLawrence (author)  electronfan2 years ago
Thanks for the comment and kind words. This was a university project and we all received the exactly same radio circuit board which we had hacked previously, although we could add components and change the circuit i hadn't had much experience in electronics and time is always tight. The speaker is pretty good and is very loud anyway but could always be better! I didn't add any isolating "stuff" because i thought the sound output was ok (and time issues / experience issues). I would definitely like to change many things within the project itself this is just the end result when i finished my module its by far not a finish product and needs plenty of work which i would love to come back to at some point. Thanks again for the feedback and support!
static2 years ago
Great construction, and nice looking cabinet... I hate to be critical, but I can't see the "dial", and the donor radio looked to have a decent slide rule dial, meaning somewhat easier to tune in the stations.
JonnyLawrence (author)  static2 years ago
Cabinet? Constructive criticism is always welcome, Im not sure what you don't understand. The dials are the two knobs at the front of the radio and the donor radio had just two cogs attached to the circuit board which i built the knobs on too. I can assure you it still works just as efficiently and easily as before. Thanks for the comment.
splazem2 years ago
Great Job!
JonnyLawrence (author)  splazem2 years ago
Thanks.
pfred22 years ago
Did you come up with that method of box construction yourself?
JonnyLawrence (author)  pfred22 years ago
Yes i did, the entire radio was designed and built by me. Im in 2nd year of product design at university of Dundee and our class had to design and make a radio for this semester and this instructable is one of the assessments. Thanks for the comment.
It looks like you are trying to invent the half frame to me.  Hopefully you won't find out why full frame panels have been around for a long time, and why the panel pieces float in the frame. So good luck, you may need it.
JonnyLawrence (author)  pfred22 years ago
Ah i had no knowledge of any of those, i just had the idea in my head and wanted to do it from the very start of my design process for a decorative feature thanks for the feedback. Im not sure what i have done fully but im glad you like it and thanks for the kind words. The radio project is actually completely finished but thanks for the luck hopefully ill receive a good grade!
JonnyLawrence (author) 2 years ago
Thanks.
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