Introduction: Gramophone Dock AKA Shiny Metal Papercraft

About: Professional work in various electrical and mechanical fields, obscure sense of humour and typically willing to help... Currently under contract designing environmental monitoring equipment.

A Google search for a Gramophone dock shows many choices.

One I found on this site by Robives

I like the simplicity and easy construction.

The design transfers quickly to thin metal.

Step 1: Gather Supplies

I selected several 4in y 10 in sheets of 0.05 brass from a hobby shop
2 pine slats 1 in by 1/4 inch thick
poly wood glue
wood stain

Solder iron or torch
wood clamps
sander and sand paper

Step 2: Make the Sound Chamber

Download the template from Robives

Print and cut the shapes for the horn, sound chamber, and adapter

trace the shapes onto the brass sheets.

The brass is thin enough to cut with scissors but I used light shears.

Treat the brass like paper and fold it with a straight edge of light bending brake.

Clean the brass edges the apply flux and solder.

Step 3: Start With the Base

Look at the model provided by Robives then map out how you want the finished product to look.

You will need to make the base from wood since the horn would be a lot heavier than paper.

I built the one shown quickly, without plans.

Prior to cutting the slats I glued 2 together on the edge to make a wide slat.

Measure the width needed from the sound chamber part of the horn.

Cut the cross piece so that the sound chamber is the max width.
Cut a second that is 1/2 inch narrower than the first

The side supports have the same front angle as the paper-craft but it is extended 3/4 of an inch back and then the back is angled down as shown.

The pieces are glued together and sanded on a belt sander.

Hand sanding makes a smooth finish then the whole base i stained to a desired colour.

Step 4: Meanwhile...

Cut and shape the remaining brass pieces.

I used one paper piece to make a template from stainless for all duplicate pieces.

All fold lines are made by pulling the back side of an x-acto knife along the paper fold line.

I decided to change the design so that the securing tabs are on the outside of the horn instead of inside on the paper model.

Step 5: Solder the Shapes

Following the paper-craft instructions, assemble the model and use solder and flux to join the metal.

I find that applying flux to the overlapping pieces then placing a small strip of solder to the joint.

The joint is then heated with a butane torch.

Continue until the model is complete.

Step 6: Oooh Shiny!

Using a Dremel and a cloth polishing wheel, remove the oxidization and create a nice shine.

Be careful on the polishing wheel as the metal is rather light weight and will bend or rip easily

Step 7: Attach to Base and Enjoy

Use poly glue to attach the sound chamber to the wooden base.

Clamp the glued pieces together as needed while the glue dries.

once dry, place the horn into the sound chamber. place the phone on the sound chamber and enjoy...

I Could Make That Contest

Participated in the
I Could Make That Contest