This is a step-by-step guide of how I manufactured the radio.
Step 1: Exploded View
Plastic Cup (to suit size of circuit board)
High Density Modelling Polystyrene
Circuit Board and Components (from Sony Radio ICF-S22)
Step 2: Hacking the original radio
The photographs show a few of the stages.
Step 3: Changing the circuit board
Step 4: Manufacturing the main body
The top component was made on the lathe, it is made using High Density Modelling Polystyrene. I used the lathe in order to create the desired dome shape. The base of the dome was 77mm.
The dome was originally going to be used to be vacuum formed using acrylic. I experimented with this but decided to use the HD Polystyrene in the final prototype.
Step 5: Manufacturing the component band
The MDF had sections cut out of it so that the controls could fit in. The situations of these holes can be changed to what you desire.
FM/AM switch: 11mm x 7mm
On/Off and Volume control: 18mm x 6mm
Headphone: 8mm (diameter)
Tuner: 28mm x 8mm
These measurements are taken from the components and outer casing of the Sony ICF-S22.
Step 6: Assembling the radio
The control components (tuner, FM/AM switch, headphone jack and on/off button) are situated on the control band.
This is then glued to the lid, this whole component then comes off to gain access to the battery pack.