DIAL COVER REPLACEMENTS
Solutions to your missing or damaged
glass and plastic dial covers.
I CAN PROVIDE A KIT OF THE IDEAL WOOD FOR
MOLDS, PROTECTED PLASTIC AND
A SHEET OF INSTRUCTIONS FOR MAKING YOUR OWN PLASTIC DIAL COVERS.
THESE DIAL COVERS ARE THE SAME AS THE ONES I MADE OVER 5000 OF BEFORE MY
STROKE. NO VACUUM DEVICE IS REQUIRED, THE PLASTIC IS NOT OF THE TYPE NORMALLY
HOBBY STORES FOR THE MAKING OF COCKPITS AND SUCH. THE INSTRUCTIONS ARE
COMPLETE IN EVERY WAY.
THE KIT CONSISTS OF SIX PIECES OF PLASTIC 6 1/2"
x 6 1/2", SIX PIECES OF FIVE PLY PLYWOOD 6 1/2" X 6 1/2" AND A PAGE OF
INSTRUCTIONS WHICH ARE THE RESULT OF PRODUCING OVER 5000 PLASTIC DIALCOVERS
OVER THE PAST YEARS. MY STROKE HAS LEFT IT IMPOSSIBLE FOR ME TO CONTINUE
MAKING THEM FOR YOU. POSTAGE IS INCLUDED IN THE PRICE AS IS NORMAL FOR ALL
PRICE FOR THE KIT IS $20.00 OR ABOUT
$3.00 PER UNIT.
Due to many requests for a kit which includes materials for
larger dial covers I am now offering a LARGE KIT with three (3) 11 x 11 inch
pieces of the correct plastic and three pieces of mold material (plywood).
Same price as above. Please specify which kit you need when ordering.
MOLDED PLASTIC DIAL COVERS
Here is my technique used for making dial covers
This kit contains the special
dial cover plastic with protective film on each side and 1/4" Baltic Birch
five-ply plywood to make the molds. Depending on the kit size you will have
six sheets of 6-1/2" square plastic and plywood or three sheets of 11" square
plastic and plywood. In addition to this you will need a jig saw (scroll
saw) using a .018" x .100"wide sawblade having 15 teeth per inch.
* * *
To begin remove the old dial cover and clean out the dial opening of any
remaining cover pieces or dirt. Make a transfer pattern of the dial opening
in order to make a mold. Take a piece of cardboard or heavy paper and place
it inside the cabinet. Hold it tightly against the front and trace an outline
of the inside of the dial opening.
Now that you have the pattern drawn, cut it out along the tracing line
starting from the outside edge of the sheet and cut in to the line. Save
the inner part that you cut out and discard the leftover surrounding piece.
Try the pattern to check its size and shape against the hole in the radio.
Verify that the pattern fits easily inside the opening without binding and
that it matches the shape.
The finished mold will consist of two parts, an inner solid piece the size
and shape of the dial cover and an outer sheet with a hole matching the
inner mold. For the mold, use a sheet of the 1/4" plywood. Place the previously
made paper/cardboard pattern in the center of the plywood and draw a line
around the outside of it. Cut out both halves of the mold in one operation
saving both the 'hole' and the surrounding piece. Start at the outside edge
of the plywood and cut in towards the outlined area. When you reach the
outlined area cut along the center of the line all the way around then remove
the piece from the inside.
After you cut out the mold, lightly sand the edges with sandpaper or 3M
sanding sponge to smooth out and straighten any rough areas while being careful
not to bevel the edges too much. The finished dial will closely match the
shape and and surface of the inner mold much like stretching a balloon over
a book. If the dial cover should have a smooth rounded edge then smooth out
the edges of the mold to the desired shape matching the original cover.
Cut out a piece of plastic at least an inch larger on all sides than the
old dial cover. You can trim it to actual size after it has been molded.
Before you place the plastic on the mold you should smooth out any wrinkles
in the protective film covering the plastic. Stack the parts starting with
a piece of plywood as a base a little bit larger than the mold parts. Place
the inner mold in the center of the base and center the plastic on top of
it. Place the outer mold on top of the plastic sheet and center the hole
over the inner mold below.
Preheat your oven to 250 degrees F. When the oven is ready put the mold
stack in and allow it to heat for 8 to 10 minutes. Wear gloves and remove
the stack from the oven. Place the mold on a sturdy flat surface. Press
down on the outer mold forcing the plastic film down over the inner mold
until the outer mold is flat against the base. Use spring clamps to hold
it together while it cools. You can put it in the freezer for 5 minutes
to cool, if desired.
After the mold is cool take it apart and remove the plastic. Trim the
edges of the dial cover so that it will fit inside the radio or bezel leaving
enoungh around the outside edge to attach it to the case as necessary. Peel
away the protective plastic film from the cover. Place the cover in the
opening and secure it with whatever means the manufacturer used.
Thanks to Dan Schoo for this write-up.
10 each BRASS EYELETS,
.056 diameter by 1/8" long. Perfect for attaching dial covers to metal
bezels. $2.00/pkg 10.
10 each BRASS EYELETS, .071 diameter by 3/16"long. Perfect for attaching
dial covers to plastic bezels. $2.00/pkg 10.
* * *
I do not sell any type of printed dials or printed dial glass scales.
Places to check for a replacement would be:
I have available convex and flat glass replacements in round only, sorry
no oval shapes. Sizes available range from 2" to 12-1/2" and they come in
1/16" increments so measure accurately before ordering. Click this link for a listing
of what is available.
has a line of printed
glass dial scales and now handles the line of decals and plastic dial reproductions
formerly done by Rock Sea Enterprises.
also carries the line
of printed dial scales previously produced by Clint Blais
including Zenith, RCA and Philco.
* * *
ROUND (FLAT) AND CONVEX GLASS DIAL COVERS
First Class Mail postage in the USA is included in the $16.00 price for
the glass. 8-inch and greater are $20.00. If you desire Priority Mail or
International Mail please submit the amount for additional postage.