Constructing the "Radio" case

Construction of Case. ( below ) no 1 support on the right  and corresponding support on the left  (not marked ) are used to support and hold upright the two side panels ,
The back panel ( lying flat should be the same width as the width of the faceplate,
No 3 is keeping the two square lats firmly in position while the wood glue is drying,
No 4 is keeping the faceplate in this position to insure the two sides are square in the construction,
No 5 is a scrap piece of aluminium strip which have the two ends bent at right angles this is pushed down tightly insuring both sides are pulling in tight to keep the frame square, 

Another view of case being constructed

( Below )The two pieces of angle Aluminium  bolted to case are to support the main internal body of  the           " Radio "  the "Radio" part of this model can be pushed in to the case on the two supports and fixed in place with the four retaining screws  which go through the four corners of the front face plate. 

Small backing sheet fixed to lower frame, this is to hide the wood strips which make up the frame.

This frame is to support another horizontal flat bar which in turn will support the handle & ariel base.

The two upright angles here will support the face plate with four bolts which pass through the faceplate and will thread in to four threaded holes on the front surface of the angle iron ( holes not yet bored here )  

Various photos of one of the four retaining bolts used to hold the faceplate in position in the case. 

front of retaining bolt with slot, circular grove,  &  painted.

( Below ) Horizontal flat bar fitted to support carrying handle & ariel support base.

these are the positions for the carrying handle and the ariel support,  
( carrying handle will not "come adrift " from case when being transported with this arrangement )

( Below ) square backing frame added here for extra support for wood box construction.

square welded metal frame to support weight of " Radio " case, this frame is held in position with  a series of small screws.

the lugs which are attached to the transporting straps should be fastened securly to the body of the 
" Radio"  ( this arrangement will ensure that the lugs will not "come adrift " from the case when being transported )

alternative version of above

underside of top panel showing bolts and fastening arrangement's for carrying handle, lugs for carrying straps, and bolt's for securing external areal fitting's.

( Below ) Aluminium angle is used here for the corners, this is 2 mm x 20 mm,
a 3 mm drill bit is used for to drill the holes on the angle piece for the screws,
an 8 mm drill bit is used for to countersink the 3mm drilled hole, this will allow the screw to be level with 
the surface of the angle piece.
the screws used here are 3 mm x 11mm.  a 1mm drill bit should be used to drill the wood frame to allow the screws to screw in with no effort.

the 11mm screw used here will project through the sheet construction of the case,
the only place where this will be a problem will be around the front of the case, the tips of the screws can be filed off flush to give the construction a smooth finish.

Aluminium band being fitted to radio case.

Aluminium band fitted in place.

when all the screws are in place a two part resin mixture should be applied to the hole where the screws are fitted, when this has hardened it can be filed or sanded off  level with the surface, & then sprayed with an under coat primer to give this rivet, or spot weld effect.

Construction of support loops  for carrying straps,          the measurement's for the diameter of the circle
                                                                                                 are 18 mm long x 16 mm wide these are original                                                                                                                                            
                                                                                                 measurement's from a Torn eb
                                                                                                 the measurements in the pictures are 21mm x 
                                                                                                 17 mm, I made these loops from studying some                                                                                              
                                                                                                 Photographs.

Safety note 
wear safety goggles for this operation.

grind to shape on grinding stone

trial & error is required here to get the shape just right

this is a small d.i.y. grinder.

when all loops are finished to your satisfaction spray paint to complete the job.

This is an update on the previous measurements.
These two pictures are photos of the loops on an original
Torn  fu. d2. Radio.

Top & side supports in place

top carrying handle's and side latches are available from hardware store's

Side loops.

Side loops with tag for fixing to side of "Radio" case. 

This is my "Jig" for constructing the loops.

the loop is constructed from a 4mm stainless steel rod.  ( look at picture sequence from photo no 1 )

Construction of lugs to hold loops.

the piece of aluminium used to make the lugs for the loops on this model measures.
total length 86 mm.

two small notches are filed in to the sides to give the loop a neater fit.

split in the middle to give each side the length of 43 mm.
the sheet is 2 mm. thick approx

fold strip over loop and press in to shape with bench vice 


be aware of the method of pressing the lug on to the loop.

if the aluminium lug is pressed on to the loop this way
the result will be as below.

this picture shows both sides of the " lug "  "crimped " with the same shape & contour on both sides,   ( this is not the result we want.)

if the aluminium lug is pressed on to the loop this way ( note the insertion of a piece of angle iron in to the vice jaws this will give the required shape as below.

this is the shape we require one flat side as indicated by the arrow, this side fits flat against the case of the " Radio. "

loops in place on the "radio" case. ( modern screws are shown here but period type screws can be made )