That's some "stuff" right there man.
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CK5
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1st gen custom radio "build"
- Thread starter bp71k5
- Start date
bp71k5
3/4 ton status
Got the new faceplate back
So I got the machined acrylic faceplate back and it looks like it will work well. It was much cheaper than I expected. Free! (I'll buy him a burrito or something later) I used a slightly tinted grey acrylic which will let the display shine through, but kinda hide the electronics a bit more than clear would. The tricky part will be mounting it onto the dash.
So I got the machined acrylic faceplate back and it looks like it will work well. It was much cheaper than I expected. Free! (I'll buy him a burrito or something later) I used a slightly tinted grey acrylic which will let the display shine through, but kinda hide the electronics a bit more than clear would. The tricky part will be mounting it onto the dash.
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bp71k5
3/4 ton status
Here's a few pictures of how it attaches to the electronics. I kept the back half of the detachable faceplate cover since it fit the electronics perfectly and had mounting holes already in it. The machined part I had made basically replaces the front half of the faceplate that you see.
You can see the two control knobs poking through each side where the old knobs were located. I have some plans on how to attach the old radio knobs onto these.
You can see the two control knobs poking through each side where the old knobs were located. I have some plans on how to attach the old radio knobs onto these.
bp71k5
3/4 ton status
And here's what it looks like behind the dash opening. I bought a spare radio on ebay to use in case I trashed the first one. You can see the knobs are the same distance apart and the chrome faceplate slides right on top of the acrylic faceplate I had machined.
I did have a nice change of plans on how to keep it all together...
Since I was able to mount everything to the same backcover from the detachable faceplate, this new faceplate assembly will snap right back onto where the base unit does. I won't have to make any weird brackets to keep the faceplate attached to the base unit. So when it's done, the radio will be just a modern radio with a vintage faceplate on it. The CD player portion is the only thing that won't work (CD's can't fit through the dash). But since my iPod has all 500+ of my CD's on it, it will plug right into this radio and I can control it from the radio as well.
I also tested the radio to make sure I didn't screw up anything when resoldering the knobs back on. It seems to work fine! There's lots of lights on it so I'm wondering how those will look when it's all put back together.
What's next?
The selector knobs are going to be trickier than I thought. I'm probably going to actually have to pay my friend to machine a custom set of knobs. Since the new radio has 7 buttons in that area, and the old radio only has five, I'm going to have to either split a couple of the buttons into two sections. I could also just make the knobs one big chunck of plastic that just looks like the old buttons and have small buttons that are flush with them. (Hard to explain, but I'll post pictures when it's done)
I also have to find a way to actually attach it to the dash. I think I can use a similar kind of washer/bracket on each of the knob holes, but I will probably have to fab something up to do it.
I did have a nice change of plans on how to keep it all together...
Since I was able to mount everything to the same backcover from the detachable faceplate, this new faceplate assembly will snap right back onto where the base unit does. I won't have to make any weird brackets to keep the faceplate attached to the base unit. So when it's done, the radio will be just a modern radio with a vintage faceplate on it. The CD player portion is the only thing that won't work (CD's can't fit through the dash). But since my iPod has all 500+ of my CD's on it, it will plug right into this radio and I can control it from the radio as well.
I also tested the radio to make sure I didn't screw up anything when resoldering the knobs back on. It seems to work fine! There's lots of lights on it so I'm wondering how those will look when it's all put back together.
What's next?
The selector knobs are going to be trickier than I thought. I'm probably going to actually have to pay my friend to machine a custom set of knobs. Since the new radio has 7 buttons in that area, and the old radio only has five, I'm going to have to either split a couple of the buttons into two sections. I could also just make the knobs one big chunck of plastic that just looks like the old buttons and have small buttons that are flush with them. (Hard to explain, but I'll post pictures when it's done)
I also have to find a way to actually attach it to the dash. I think I can use a similar kind of washer/bracket on each of the knob holes, but I will probably have to fab something up to do it.
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Kudos man...hope nobody decides to steal your mint looking stock radio.
bp71k5
3/4 ton status
I guess if someone did swipe it would be pretty hard to use it in anything but a 69-72. I'd have a short list of trucks to look for it. 
greythorn3
1/2 ton status
wow
its like science fiction!!!
Ray
its like science fiction!!!
Ray
bp71k5
3/4 ton status
Dash opening repair
Here's a quick picture of the buttons I'm having built for the radio. I needed 8 buttons to fit in the space where 5 old buttons were. So I designed replicas of the old buttons and shrunk the width of a couple to make everything fit. I also had to design a way for them to activate the little switches on the radio board. It was kinda tricky.
Here's a quick picture of the buttons I'm having built for the radio. I needed 8 buttons to fit in the space where 5 old buttons were. So I designed replicas of the old buttons and shrunk the width of a couple to make everything fit. I also had to design a way for them to activate the little switches on the radio board. It was kinda tricky.
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bp71k5
3/4 ton status
While I'm waiting for the new buttons for the radio to be finished, I thought I'd tackle the hacked out opening in the dash.
I had a large dash section I cut from a wrecking yard truck. One option the experts have to replace the radio opening is to cut the entire large section of the dash out and weld in a replacement. Most of the welds are covered by the gauge cluster and the glove box. This is a pretty good idea, but requires taking the whole dash apart and it requires you to cut a metal support plate at the bottom of the dash. I had already cut tons of original sheetmetal out so I wanted to avoid more if I could.
I decided to patch in a smaller panel just the size of the radio opening. This allowed me to keep the dash intact, and keep the repair isolated to the radio area. It is risky though since you need to do very careful welding to keep this highly visible area from warping.
Here's where I cut. I'm adding AC at the same time so that's the reason for the odd cut at the top.
I first cut out the section on the patch panel I wanted to use and used it as a template to trace the opening on my dash that needed to be cut.
Then I carefully fit the patch into the opening and filed here and there to get an exact fit. I used a few clamps to keep the patch flush with the dash.
Then I stitch welded the panel every so often to keep the heat down and prevent warping. One welding trick I've found on sheetmetal using fluxcore (don't have the gas yet) is that to keep the weld material from building up, you can turn up the amperage and hit the joint just long enough to spark and then turn it off. This seems to give a really good weld without much weld slag or buildup. You can see the pictures show a few rounds of this.
Also remember to protect the inner dash area (with the wires!) to keep sparks from causing any trouble there.
I had a large dash section I cut from a wrecking yard truck. One option the experts have to replace the radio opening is to cut the entire large section of the dash out and weld in a replacement. Most of the welds are covered by the gauge cluster and the glove box. This is a pretty good idea, but requires taking the whole dash apart and it requires you to cut a metal support plate at the bottom of the dash. I had already cut tons of original sheetmetal out so I wanted to avoid more if I could.
I decided to patch in a smaller panel just the size of the radio opening. This allowed me to keep the dash intact, and keep the repair isolated to the radio area. It is risky though since you need to do very careful welding to keep this highly visible area from warping.
Here's where I cut. I'm adding AC at the same time so that's the reason for the odd cut at the top.
I first cut out the section on the patch panel I wanted to use and used it as a template to trace the opening on my dash that needed to be cut.
Then I carefully fit the patch into the opening and filed here and there to get an exact fit. I used a few clamps to keep the patch flush with the dash.
Then I stitch welded the panel every so often to keep the heat down and prevent warping. One welding trick I've found on sheetmetal using fluxcore (don't have the gas yet) is that to keep the weld material from building up, you can turn up the amperage and hit the joint just long enough to spark and then turn it off. This seems to give a really good weld without much weld slag or buildup. You can see the pictures show a few rounds of this.
Also remember to protect the inner dash area (with the wires!) to keep sparks from causing any trouble there.
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bp71k5
3/4 ton status
Once the welding was done, I carefully ground the surface flush with a angle grinder using a sanding disc attachement. The disc is a little more forgiving and less likely to gouge the surrounding area if I "slip".
Then a little body filler to fill in the imperfections and it's ready for primer.
Then a little body filler to fill in the imperfections and it's ready for primer.
supersize75k5
OrganDonorRacing.com
update?
man im loving this
man im loving this
bp71k5
3/4 ton status
Dash radio opening patch complete
Here's the final pic of the repaired dash opening for the radio. It just has a coat of primer and will stay that way for a while till I redo the interior. It turned out real well with no weird dimples or deformed parts. This was definately the trickiest welding I've done.
Still waiting on the buttons to come back...
Here's the final pic of the repaired dash opening for the radio. It just has a coat of primer and will stay that way for a while till I redo the interior. It turned out real well with no weird dimples or deformed parts. This was definately the trickiest welding I've done.
Still waiting on the buttons to come back...
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Yukon Jack
1/2 ton status
Very nice. I see some people get so worked up about dashes that have or are going to be cut - but as this shows, everything can be returned to stock if needed. Just takes some welding skills and effort.
bp71k5
3/4 ton status
Thanks, I'm pretty pleased with it. I'm glad I practiced welding on the rockers first since that was my first time welding thin sheetmetal. The dash would have turned out pretty rough if I didn't figure out how to keep the beads clean and low.
I had originally thought these dash patch panels would be hard to find, but I found 4 of them in a local wrecking yard. They are easy to cut out and super cheap. If anyone needs one, let me know.
I had originally thought these dash patch panels would be hard to find, but I found 4 of them in a local wrecking yard. They are easy to cut out and super cheap. If anyone needs one, let me know.
bp71k5
3/4 ton status
Update 9 months later
I finally got my machining work done after 9 months on the buttons for this custom stereo. It took a few hours of tweaking the fit with my dremel to get the buttons to actuate smoothly. They are still raw ABS plastic but will be painted black to match the originals style.
You can see there are now 8 buttons that control the 6 presets, 1 menu, and 1 source toggle to switch between the different inputs. The two knobs are attached to more modern joystick type controls.
I still need to attach some more screws and maybe a little epoxy on a few parts together to make sure it survives. I also have to fab up some mounting washers similar to the originals so it attached to the opening in the dash.
I haven't fired it up in 9 months so I hope it still works. I'm kinda stoked since this appears to be working out pretty well.
I finally got my machining work done after 9 months on the buttons for this custom stereo. It took a few hours of tweaking the fit with my dremel to get the buttons to actuate smoothly. They are still raw ABS plastic but will be painted black to match the originals style.
You can see there are now 8 buttons that control the 6 presets, 1 menu, and 1 source toggle to switch between the different inputs. The two knobs are attached to more modern joystick type controls.
I still need to attach some more screws and maybe a little epoxy on a few parts together to make sure it survives. I also have to fab up some mounting washers similar to the originals so it attached to the opening in the dash.
I haven't fired it up in 9 months so I hope it still works. I'm kinda stoked since this appears to be working out pretty well.
Yukon Jack
1/2 ton status
Ha, quoting myself! Such a cool project, I continue to be eager to see your finished product!!!
Update?
Don't you hate seeing cool build threads that suddenly stop getting updated....
Indeed, I do...
bp71k5
3/4 ton status
Don't you hate seeing cool build threads that suddenly stop getting updated....
Yea, what's up with that? I guess you have a better excuse than me though.
Congratulations! by the way.There's a fine balance between how much time you spend in the garage vs. how much time your wife makes you spend in the doghouse (if you know what I mean )
The radio has been taking a back seat to the motor install, but I'll have an update (with pictures) in about 2-3 business days. Seriously, I ordered some new machined parts about 2 hours ago. The old parts didn't quite fit right and wouldn't have been very reliable if I used them on the truck.
