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New Face

This weekend had me working on replacing the face of the console where the tuner is mounted. The old face came out easily… just had to remove about a dozen screws and give it a few taps to loosen it up. It wasn't glued, but the original lacquer finish held it in place some.

Then I had to come up with a way to mount the new radio. I took the new radio out of its case. It came out pretty easily. Just four screws held it together and another pair of screws secured to a pair or retaining clips. I discovered the radio was essentially two parts… the tuner, and the amp. They were held together by four screws that sort of clamped itself together inside the case.

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Now knowing how it assembled together, I came up with a way to mount it to the new face using the four screw mounts.

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To make the face I began with some scrap ¼" marine plywood I had in the shop and glued a 1/16" thick mahogany veneer to it that was left over from my last project (I need to make myself a veneer press one of these days). This is thinner that the original face, but the marine plywood is better quality and stronger even though its thinner.

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Then I trimmed it to size and cut bevels to match the old face and also made a cutout to mount the new radio.

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The old face was made with a spline to join the front and top together. This was doable because the face was ⅜" thick. I felt my new face was too thin to use a spline so I put my boat building skills to work and epoxied them together utilizing an epoxy fillet.

First I made a clamping mold.
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Then I taped the two pieces together with packing tape that acted as both a hinge and a means to temporarily hold the two pieces together.
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Then I applied thickened epoxy to the seam, folded it in place in the mold, clamped it, then applied the epoxy fillet. Note that I also laid down some packing tape to the mold so that I didn't accidentally epoxy the face to the mold.

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After curing for 24 hours it came out pretty decent.

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Great job Pags! I have a table top version I've been wanting to rehab and didn't know where to start and you've given me some ideas. Thanks!
 

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