Reproduction Torn eb
Posted: Mon Sep 15, 2014 3:29 pm
Here is my completed radio set. It took me many weekends over the course of 2 years and approximately $250.00 to complete. From my experience building the Torn fu d2 (posted on this site), the boxes, pad, batteries were easier to build. However the dial workings of the faceplate were much more challenging. All the knobs spin rotating their appropriate dial indicator on the opposite side of the faceplate.
BOXES:
I used ¼” Masonite, 1” aluminum angle and flat stock and aluminum rivets. These items can be purchased at Home Depot, Lowes and Hanson Rivet. I chose Masonite because it looks like steel when painted and sealed (this time I used the type used for dry erase boards). The angle stock was partially mitered and wrapped around the box and covers and then riveted in place. The boxes are fairly solid when braced with the angle stock regardless of the flexibility of the Masonite.
BOX DETAILS:
The footman loops (purchased from ACE Hardware) bolted on using self locking nuts.
Latches (purchased on ebay) riveted in place.
Back pad brackets fabricated from slightly thicker sheet metal riveted in place.
Handles bolted on using self locking nuts and large washers on the inside to prevent potential tear-out if the handle is yanked.
Leather handle made from scrap French “Y” Straps.
Battery Plug door routed from a piece of pine, lever made from wood, glued into place.
Shelves and compartments fabricated from Masonite and angle stock riveted in place.
BACK PAD:
Fabricated from Masonite, foam padding, faux leather (purchased from Joann’s Crafts) sheet metal strips and aluminum rivets.
BATTERIES:
90 Volt batterie fabricated from wood covered in black construction paper, label applied and glued and covered in Mod Podge glue. Leather strap (Czech straps purchased from Sportsman’s Guide) attached to back. The battery itself is attached to the box through shelf holes with bolts anchoring into “T nuts” in the base on the battery.
Sammler Battery fabricated from wood covered, painted. Wire terminals are Allen bolts with the slot filled in with metal filler and painted. Leather strap (Czech straps purchased from Sportsman’s Guide) attached to back. The battery itself is attached to the box through divider holes with bolts anchoring into “T nuts” in the side of the battery.
FACEPLATE:
Resin face plate (purchase from Brad Blondett), Drilled holes for audio jacks and knob shafts, removed cast switches.
Used small hollow rods (purchased from hobby shop) to reinforce holes and glue into backs of knobs.
Fabricated dials out of sheet plastic (purchased from hobby shop) used copy of a graduated dial and taped to plastic dial using clear packing tape.
Installed two moveable light stitches.
Used gear sprockets from model RC helicopter to engage dials and rotors.
Installed 1/8” audio jacks (headphones), cut away some of the insulation to facilitate installation (purchased from Radio Shack) and glued using Krazy Glue.
Used a magnet mounted on the inner frame as a fastener for the battery plug with a metal washer glued to the face of the plug.
NOTES:
The face plate is mounted to a frame that is built into the box. Two bolts are installed through the frame and act as the grounding terminals that hold both the faceplate and the dummy antenna and ground leads in place.
One 1/8” audio 3 way “y” splitters are used for the ipod.
The inside of the radio box is lined with foam padding to hold the devices in place.
PAINTING & FINISHING:
All resin parts primed with model primer. Used Rustoleum Dark Gray primes and Urban Gray Krylon Camo Spray Paint (now discontinued) to paint boxes, covers, faceplate, back pads, and then sealed with Krylon 2 Coat Sealer.
Painted dials, volt meter, and bezels with black model paint. Used white acrylic paint for text as well as a paint pen.
HEADPHONES:
Bought an old vintage 1950’s headset from eBay ($10.00) and replaced plug with a modern 1/8” plug (purchased from Radio Shack).
BOXES:
I used ¼” Masonite, 1” aluminum angle and flat stock and aluminum rivets. These items can be purchased at Home Depot, Lowes and Hanson Rivet. I chose Masonite because it looks like steel when painted and sealed (this time I used the type used for dry erase boards). The angle stock was partially mitered and wrapped around the box and covers and then riveted in place. The boxes are fairly solid when braced with the angle stock regardless of the flexibility of the Masonite.
BOX DETAILS:
The footman loops (purchased from ACE Hardware) bolted on using self locking nuts.
Latches (purchased on ebay) riveted in place.
Back pad brackets fabricated from slightly thicker sheet metal riveted in place.
Handles bolted on using self locking nuts and large washers on the inside to prevent potential tear-out if the handle is yanked.
Leather handle made from scrap French “Y” Straps.
Battery Plug door routed from a piece of pine, lever made from wood, glued into place.
Shelves and compartments fabricated from Masonite and angle stock riveted in place.
BACK PAD:
Fabricated from Masonite, foam padding, faux leather (purchased from Joann’s Crafts) sheet metal strips and aluminum rivets.
BATTERIES:
90 Volt batterie fabricated from wood covered in black construction paper, label applied and glued and covered in Mod Podge glue. Leather strap (Czech straps purchased from Sportsman’s Guide) attached to back. The battery itself is attached to the box through shelf holes with bolts anchoring into “T nuts” in the base on the battery.
Sammler Battery fabricated from wood covered, painted. Wire terminals are Allen bolts with the slot filled in with metal filler and painted. Leather strap (Czech straps purchased from Sportsman’s Guide) attached to back. The battery itself is attached to the box through divider holes with bolts anchoring into “T nuts” in the side of the battery.
FACEPLATE:
Resin face plate (purchase from Brad Blondett), Drilled holes for audio jacks and knob shafts, removed cast switches.
Used small hollow rods (purchased from hobby shop) to reinforce holes and glue into backs of knobs.
Fabricated dials out of sheet plastic (purchased from hobby shop) used copy of a graduated dial and taped to plastic dial using clear packing tape.
Installed two moveable light stitches.
Used gear sprockets from model RC helicopter to engage dials and rotors.
Installed 1/8” audio jacks (headphones), cut away some of the insulation to facilitate installation (purchased from Radio Shack) and glued using Krazy Glue.
Used a magnet mounted on the inner frame as a fastener for the battery plug with a metal washer glued to the face of the plug.
NOTES:
The face plate is mounted to a frame that is built into the box. Two bolts are installed through the frame and act as the grounding terminals that hold both the faceplate and the dummy antenna and ground leads in place.
One 1/8” audio 3 way “y” splitters are used for the ipod.
The inside of the radio box is lined with foam padding to hold the devices in place.
PAINTING & FINISHING:
All resin parts primed with model primer. Used Rustoleum Dark Gray primes and Urban Gray Krylon Camo Spray Paint (now discontinued) to paint boxes, covers, faceplate, back pads, and then sealed with Krylon 2 Coat Sealer.
Painted dials, volt meter, and bezels with black model paint. Used white acrylic paint for text as well as a paint pen.
HEADPHONES:
Bought an old vintage 1950’s headset from eBay ($10.00) and replaced plug with a modern 1/8” plug (purchased from Radio Shack).
