Introduction: GTO Radio : Hacking a Radio for Nostalgic Motorists
The GTO radio is designed to bring classic American muscle and the powerful presence of radio together in one easy to use product. Its carefully selected materials have been chosen to create an aesthetically pleasing yet user friendly radio.
With this step by step guide, you too can build a radio like the one shown here or feel free to make changes to suit you.
With this step by step guide, you too can build a radio like the one shown here or feel free to make changes to suit you.
Step 1: Exploded View and Materials
Materials:
420mm x 297mm x 4mm MDF x3
420mm x 297mm x 9mm MDF
Sanding sealer
Primer
Super gloss paint x2
Wood glue
Super glue
A portable radio (Sony ICF-S22)
Button switch
Chrome guitar knob x2
Petri dish x2
Mount board
Metal rod radius: 2mm length: 600mm
Cogs Diameter 44mm x4
Cogs Diameter 33mm x2
Glossy photo paper
420mm x 297mm x 4mm MDF x3
420mm x 297mm x 9mm MDF
Sanding sealer
Primer
Super gloss paint x2
Wood glue
Super glue
A portable radio (Sony ICF-S22)
Button switch
Chrome guitar knob x2
Petri dish x2
Mount board
Metal rod radius: 2mm length: 600mm
Cogs Diameter 44mm x4
Cogs Diameter 33mm x2
Glossy photo paper
Step 2: Hacking the Radio
Carefully dismantle the portable radio and remove the components. In this case I am using a Sony ICF-S22.
Desolder the components that need to be relocated or extended. These are the volume control, the loudspeaker, AM/FM switch and the battery pack.
Solder them back into place using wires so that they can function without actually being fixed to the circuit board.
Cut the wire that connects the battery pack to the circuit board and solder the loose ends to the positive and negative legs on the push switch.
I replaced the AM/FM switch with a toggle switch.
I made a quick sketch model to give an idea of where the components will be.
Desolder the components that need to be relocated or extended. These are the volume control, the loudspeaker, AM/FM switch and the battery pack.
Solder them back into place using wires so that they can function without actually being fixed to the circuit board.
Cut the wire that connects the battery pack to the circuit board and solder the loose ends to the positive and negative legs on the push switch.
I replaced the AM/FM switch with a toggle switch.
I made a quick sketch model to give an idea of where the components will be.
Step 3: Making the Components Bracket
Measure and cut the 4mm MDF into the shapes shown above.
The holes measure 5mm in diameter and will house the axes for the cogs.
Assemble the bracket as shown.
The holes measure 5mm in diameter and will house the axes for the cogs.
Assemble the bracket as shown.
Step 4: Mounting the Circuit Board
Mount the circuit board into the bracket.
Step 5: Assembling the Gears
Glue the large cogs to the metal rods 30mm from the end.
Insert the end closest to the cog into the holes of the bracket.
Glue the small cogs to the remaining metal rods 10mm from the end and glue to the volume and tuning dials.
Insert the end closest to the cog into the holes of the bracket.
Glue the small cogs to the remaining metal rods 10mm from the end and glue to the volume and tuning dials.
Step 6: Cutting the Wood
Measure and cut the 9mm MDF for the radio shell using the shapes shown
Drill a hole diameter 56mm in the center of the top panel and another hole 6mm in diameter for the aerial to go through.
If you have access to a laser cutter you can cut a speaker grille like the one I did.
Cut a hole in the corner of the base. This is so you will have access to the batteries.
Drill a hole diameter 56mm in the center of the top panel and another hole 6mm in diameter for the aerial to go through.
If you have access to a laser cutter you can cut a speaker grille like the one I did.
Cut a hole in the corner of the base. This is so you will have access to the batteries.
Step 7: Assembling the Shell
Glue the front and back panels onto the base
Glue the side panels on next
Finally glue on the top panel
I made another sketch model to give you an idea of the outcome (without the white face)
Glue the side panels on next
Finally glue on the top panel
I made another sketch model to give you an idea of the outcome (without the white face)
Step 8: Sanding the Shell
Sand the edges to get nice filleted corners and buff the surfaces using fine sand paper to make it smooth.
Step 9: Varnishing in the Shell
Coat the shell with sanding sealer and sand back using fine sand paper when dry.
Repeat another two times.
Repeat another two times.
Step 10: Priming the Shell
Coat the shell in primer and leave overnight to dry
Step 11: Painting the Stripes
Mask the shell and paint on the stripes. Apply a thin even coat and leave to dry for 4 hours.
Repeat another two times.
Repeat another two times.
Step 12: Painting the Body
Mask the stripes and paint on a colour of your choice. Apply a thin coat and let dry for 4 hours.
Repeat another two times.
Repeat another two times.
Step 13: Making the Front Face
Measure and cut the 4mm MDF in the shape shown.
Varnish the cut to get a nice finish.
This will be the front face.
Varnish the cut to get a nice finish.
This will be the front face.
Step 14: Assembling the Radio
Glue the components bracket into the shell and glue the loudspeaker, the aerial and battery pack into there appropriate places.
Step 15: Sticking the Vynil
Cut and stick the vynil to the front face to create the control panels. These will connect the displays to their corresponding dials.
Step 16: Mounting the Front Face
Insert the push switch and toggle switch into the appropriate holes of the front panel and mount it onto the opening of the shell. Make sure the metal rods go through their corresponding holes. You can now cut them so that they extend out 5mm from the front.
Glue the chrome guitar knobs onto the bottom two rods.
Glue the chrome guitar knobs onto the bottom two rods.
Step 17: Assembling the Displays
Drill a hole, 4mm in diameter, through the center of each petri dish and another hole 41mm from the center.
Insert the volume meter and the frequency indicator into the petri dishes. These can be made on photoshop and printed on glossy photo paper.
Place the petri dishes into their corresponding holes in the front panel ensuring the metal rods go through the holes.
Cut out needles from mount board and stick them to the ends of the rods at the centre of the displays.
Finally cover the petri dishes by gluing on their lids.
Insert the volume meter and the frequency indicator into the petri dishes. These can be made on photoshop and printed on glossy photo paper.
Place the petri dishes into their corresponding holes in the front panel ensuring the metal rods go through the holes.
Cut out needles from mount board and stick them to the ends of the rods at the centre of the displays.
Finally cover the petri dishes by gluing on their lids.