How to Make an FM Radio at Home Using the Sony 1619 FM Radio Kit (Step-by-Step)

ERGREAT

Introduction

Building your own FM radio at home is one of the most satisfying DIY electronics projects you can try. Not only do you learn how a radio works, but you also create a fully functional device that you can proudly use every day. In this project, we will make a high-quality FM radio using the Sony 1619 FM Receiver Board, a 5W speaker, and a beautifully crafted handmade MDF enclosure. The 1619 FM board is known for its excellent signal sensitivity, clear audio output, and stable FM tuning, which makes it perfect for beginners as well as hobbyists.

Unlike readymade radios available in the market, this DIY model allows you to customize its look, feel, and build quality. You can design the enclosure the way you want, add switches, knobs, and even personalize it with paint or polish. The best part is that this project requires very simple components and basic tools that are easily available in any electronics store.

In this detailed guide, we will walk through everything—cutting the MDF panels, assembling the wooden box, installing the speaker and FM board, wiring the antenna, adding the switch, and tuning your radio for perfect sound. Everything is explained in simple, easy-to-understand language.

Let’s start with the complete step-by-step process.

Components Required

  • Sony 1619 FM Receiver Board
  • 5W Speaker
  • 9V HW Battery with Clipper
  • 6mm MDF Board
  • Volume Knob
  • Tuning Knob
  • Metal Antenna
  • SPST Switch (For ON/OFF Control)
  • Fevicol or Heatax Glue
  • Hot Glue Gun + Glue Sticks
  • Screws
  • Sandpaper (Medium & Fine)
  • Wires and Basic Tools (cutter, pliers, drill machine, screwdriver)

All these components are affordable and perfect for a beginner-level FM radio build.

📐 Step-by-Step Construction of the FM Radio

Step 1: Cutting the MDF Board Panels

We will make a strong and long-lasting enclosure using 6mm MDF board. MDF is easy to cut, durable, and perfect for electronics projects.

Cut the board into the following six pieces:

  • Front Panel: 15cm × 11cm
  • Back Panel: 15cm × 11cm
  • Top Panel: 13cm × 5cm
  • Bottom Panel: 13cm × 5cm
  • Left Side Panel: 11cm × 5cm
  • Right Side Panel: 11cm × 5cm

These six pieces will form a box-shaped enclosure.
Accurate cutting is important so the enclosure fits tightly.

Step 2: Building the Enclosure Frame

After cutting the pieces, it’s time to build the frame of the radio box.

  1. Apply Fevicol or Heatax glue to the edges.
  2. Stick the sides, top, bottom, and back panel together.
  3. Make sure the front panel is not glued at this stage.
  4. Use clamps to tightly hold the panels for perfect bonding.

Clamping is important because it prevents the panels from moving during drying and gives the enclosure a strong structure.

Allow it to dry for 1–2 hours.

Step 3: Preparing the Front Panel

The front panel needs several holes because it will hold:

  • The 5W speaker
  • The volume knob
  • The tuning knob
  • FM Receiver kit

Mark the positions first, then drill the holes neatly.

Speaker Hole:
Mark a circle equal to the speaker size and cut it using a hole saw or jigsaw tool.
Volume & Tuning Knob Holes:
Make two small round holes matching the potentiometer shaft size on the FM board.
Place the panel on the box and check alignment.
At this stage, do not permanently screw it—just test fitting.

Step 4: Front Panel Installation

Once holes are made:

  1. Position the front panel on the enclosure.
  2. Use four corner screws to attach it with the box.
  3. These screws make the panel removable, so you can open it anytime for battery replacement or repairs.

Now the enclosure looks like a real radio box.

Step 5: Sanding the Box

Take sandpaper and smoothen the entire enclosure:

  • Sand the edges
  • Smoothen the surface
  • Remove glue marks

This step gives a clean and polished finish.
You can even paint the box later if you want a premium look.

Step 6: Drill a Hole for the Power Switch

On the top side of the enclosure, drill a small hole for the SPST ON/OFF switch.
Insert the switch into the hole and tighten it so it doesn’t move.
This switch will be used to turn the radio ON or OFF.

Step 7: Installing the Antenna

The antenna improves FM reception.
Fix it on the back side panel using two small screws.

Make sure:

  • The antenna is straight
  • It is firmly attached
  • The antenna wire can easily reach the FM board

This will help you capture strong local FM signals.

Step 8: Mounting the Speaker and FM Board

Now it's time to attach the electronic components.

Mounting the Speaker

  1. Place the speaker behind the speaker hole.
  2. Use hot glue to fix it properly.
  3. Make sure it is airtight to produce good bass and clear sound.

Mounting the FM Receiver Board

  1. Apply hot glue on the back side of the board.
  2. Stick the Sony 1619 FM board carefully on the front panel.
  3. Ensure the volume and tuning potentiometers align perfectly with their respective holes.

Finally, fix the knobs on the potentiometer shafts.

Step 9: Complete the Wiring

This is the most important step.
Follow these simple wiring connections:

1. Antenna Connection

Connect the antenna wire to the FM board’s antenna terminal.
This will boost the radio signal.

2. Power Supply Connection

Connect the 9V battery clip wires in series with the SPST switch:

  • Battery (+) → SPST Switch → FM board (+)
  • Battery (-) → FM board (-)

This allows the switch to control the power.

3. Speaker Connection

Connect the speaker wires to the speaker output terminals on the FM board.
Make sure the connections are tight to avoid noise.
Double-check all wiring before closing the radio box.

Step 10: Closing the Enclosure

After wiring:

  • Insert the 9V HW battery inside the box.
  • Arrange wires neatly so nothing touches the speaker cone.
  • Close the front panel using screws again.
  • Check that the knobs rotate freely and don’t rub against the wood.

The radio is now completely enclosed and ready for testing.

Step 11: Testing the FM Radio

This is the most exciting part!
Turn ON the Radio:
Flip the SPST switch to ON.
You should hear the radio board powering up.
Adjust the Volume:
Rotate the volume knob to the right to increase volume.
Tune the Channels:
Rotate the tuning knob slowly to catch local FM stations.

With the 1619 board, you should get:

  • Smooth tuning
  • Perfect clarity
  • Stable audio
  • Zero distortion

The antenna will help receive long-distance channels clearly.

Step 12: Final Look and Performance

Your FM radio is now:

  • Fully functional
  • Strong and durable
  • Great in sound quality
  • Beautiful in appearance

The MDF enclosure gives a premium handmade look, which makes this radio perfect for:

  • Home
  • Kitchen
  • Workshops
  • Camping
  • Travel
  • Gift to family or friends
  • School/college project

You can also paint or polish the box to give it a more attractive design.

Conclusion

Making an FM radio at home using the Sony 1619 FM Radio Kit is a fun, simple, and highly educational project. With minimal tools and easily available components, you can build a powerful and professional-looking radio that works perfectly. The MDF enclosure provides strength and style, while the 1619 FM board gives excellent audio clarity and smooth tuning.

This project is ideal for beginners who want to learn electronics, students doing science projects, or hobbyists looking to create something useful. Once complete, you can proudly use your radio anywhere. With a clear sound output, strong FM reception, and a handmade look, this DIY FM radio becomes a beautiful combination of creativity and technology.

ERGREAT

Posted by ERGREAT

Hi, I’m Kishor Kumar — an electronics enthusiast, maker, and traveler from India. I love building DIY electronic projects, experimenting with circuits, creating tutorials, and sharing step-by-step guides that help others learn easily. When I’m not working on electronics, I travel across India with my cameras, capturing stories, places, and experiences that inspire my creativity. Through ERGREAT, my aim is to share practical projects, detailed explanations, and real-life adventures that motivate others to explore technology and the world around them.

Post a Comment

0 Comments