• Removed all the accessories (Y Strap Hooks, Side Cover, Audio Jacks)
• Disassembled the resin components from the MDF and poplar pieces.
• Stripped paint off of all pieces.
• Squared and trimmed edges of all pieces on the table saw.
• Cut off antenna base and "d" ring castings from top piece
• Built a 5 sided wood box out of birch and pine plywood using rabbet joints.
• Glued (contact cement) and screwed top and bottom pieces to wood box, applying clamp pressure.
• Glued (contact cement) side pieces to wood box, applying clamp pressure.
• Used two part epoxy cement to seal all seems and fill in any holes.
• Sanded all seems and holes smooth.
• Fabricated straps out of sheet metal for "d" rings and carrying handle, attached with screws, filled in slots with epoxy.
• Made faceplate dial out of plastic gear from discarded toner cartridge.
• Turned antenna base out of pine on lathe, painted black and screwed to top.
• Painted housing with gray primer 3-4 coats.
• Painted housing with Panzergrau (1944 Militaria) 3-4 coats.
• Painted faceplate with brown paint 1 coat, used paint pen to write-in texts, attached with screws to box.
• Attached leather strap (made from old French "Y" straps) and bumpers (2 on front, 2 on back).
• Installed two flat hooks on bottom (purchased from Lowe's).
• Made carrying handle out of canvas webbing with riveted metal tips.
• Reinstalled side access cover, reinstalled locking latch that came with kit.
• Cut out stencils, used flat black paint.
• Reinstalled "y" strap hooks, audio jack and antenna that came with kit.
• Attached a modified old headset (made during my Torn fu d2 build).
• Finished unit weighs just over 9 pounds.
I have a second cover that is identical to the right side I will have to make some modifications such as a switch access port and the two white message squares.
The build took me about 5 weekends and much easier than the Torn fu d2 or Torn eb. I just have to finish the second cover and try to find someone that casts the throat mikes from resin.
Hope this helps anyone trying to build one.
