DIY FM Radio — Build a FM Receiver at Home With the Sony 1619 FM Radio Kit

In this step-by-step Instructables project you'll learn to make a fully working FM radio using the Sony 1619 FM Radio kit. This easy-to-follow guide is made for beginners and hobbyists who want hands-on experience with soldering, component identification, and basic radio principles. By the end you'll have a compact FM receiver that tunes local stations, with clear instructions on assembly, alignment, testing, enclosure options, and simple troubleshooting tips.

To build your DIY FM Radio using the Sony 1619 FM Receiver kit, gather all the essential components and tools listed below. Having everything ready before starting makes the assembly smooth and hassle-free.

📦 Components Needed

1. Sony 1619 FM Receiver Board (Kit PCB + Components)
2. 5W Speaker (8Ω recommended)
3. 9V HW Battery
4. 9V Battery Clipper/Connector
5. 6mm MDF Board (for enclosure)
6. Volume Control Knob
7. FM Antenna
8. SPST Switch (On/Off Switch)

In this step, you will create the enclosure (radio cabinet) using 6mm MDF board. This box will protect your FM radio circuit and give it a clean, finished look.

📐 Cut MDF Board into the Following Sizes

Using a cutter, mini saw, or MDF cutting tool, cut the board into these exact dimensions:

1. Front Panel: 15 × 11 cm
2. Back Panel: 15 × 11 cm
3. Top Panel: 13 × 15 cm
4. Bottom Panel: 13 × 15 cm
5. Left Side Panel: 11 × 5 cm
6. Right Side Panel: 11 × 5 cm

These measurements form a compact and sturdy box to fit your FM radio assembly perfectly.

🧩 Join the Panels

Now assemble the enclosure:

1. Take the Bottom panel and place it on a flat surface.
2. Attach the Left and Right side panels vertically on the sides of the bottom panel.
3. Fix the Back panel to the structure.
4. Place and glue the Top panel to close the box frame.

Use Fevicol or Heatax adhesive for strong bonding.

👉 Do NOT attach the Front Panel yet.

You will mount the speaker, knobs, antenna, and receiver board on it in later steps.

In this step, you will work on the front panel design, make proper holes for components, mount the panel, and finish the enclosure neatly.

1. Mark and Cut Holes on the Front Panel

Take the 15 × 11 cm front MDF panel and mark the following positions:

1. Speaker Hole
2. Use a compass or round stencil to mark a circle matching your 5W speaker size.
3. Cut the hole using a cutter, jigsaw, or rotary tool.
4. Volume Knob Hole
5. Mark the exact center where the volume potentiometer will be placed and drill a small circular hole.
6. Tuning Knob Hole
7. Similarly, mark and drill another hole for the tuning potentiometer.

Make sure all holes align with the components on the 1619 FM receiver board.

2. Attach the Front Panel to the Box

After the glue on the main box (back, top, bottom, left, right panels) has fully dried:

1. Place the front panel on the box.
2. Use small screws to firmly attach the front panel to the enclosure.
3. Ensure the front panel is removable if needed by not over-tightening the screws.

This makes maintenance easier later.

3. Smooth the Entire Enclosure

Use sandpaper (100–220 grit) to rub the entire enclosure:

1. Smoothen the edges
2. Remove any rough corners
3. Prepare the surface for painting (optional)

The enclosure should feel clean and even to the touch.

4. Drill a Hole for the SPST Switch (ON/OFF)

On the top panel of the enclosure:

1. Mark a small spot near the back side.
2. Drill hole that fits the SPST toggle or slide switch.
3. Ensure the switch fits snugly and can be operated comfortably.

Your MDF Enclosure Is Now Ready!

With the panel holes, screw fittings, smoothing, and switch mount complete, the enclosure is now prepared for installing the FM receiver circuit, speaker, battery, and other components.

Now that your enclosure is ready, it’s time to mount the essential components inside it. This step ensures strong signal reception and a clean internal layout.

1. Mount the FM Antenna on the Back Panel

1. Take the FM antenna.
2. Place it on the outside back panel of the enclosure.
3. Align the base of the antenna properly.
4. Use two small screws to fix the antenna tightly on the back side.
5. Make sure the antenna is firm and can be adjusted or rotated easily for better reception.

A strong and stable antenna mount improves FM station clarity.

2. Stick the Speaker on the Front Panel

On the front panel:

1. Place the speaker behind the round hole you created earlier.
2. Apply hot glue around the edges of the speaker.
3. Firmly press the speaker onto the inside of the front panel.
4. Ensure the speaker is centered and aligned with the hole for best sound output.

Hot glue secures the speaker without damaging it.

📻 3. Mount the Sony 1619 FM Receiver Board

Next, install the FM radio board:

1. Position the 1619 FM circuit board so the volume and tuning shafts align perfectly with the holes you drilled.
2. Once aligned, apply hot glue to the sides or bottom of the PCB.
3. Hold it in place until the glue sets.
4. Make sure the board is stable and not touching the speaker cone or wires.

Proper alignment ensures the knobs will be smooth and easy to rotate.

With all major components installed, it’s time to complete the wiring, mount the front panel permanently, and test your homemade FM Radio.

1. Connect All Wires to the FM Board

Follow these connections carefully:

• Antenna Wire

1. Connect the antenna wire from the back-mounted antenna to the ANT pin on the 1619 FM Receiver board.
2. Ensure the solder joint is tight for better signal reception.

• Battery Wire & SPST Switch (in series)

1. Take the 9V battery clipper’s positive wire.
2. Pass it through the SPST switch.
3. Clip positive wire → switch → FM board +V input.
4. Connect the negative wire directly to the board’s GND.
5. This way, the SPST switch controls the ON/OFF of the radio.

• Speaker Wires

1. Connect the two speaker wires to the SPK+ and SPK− terminals on the FM board.
2. Make sure polarity is correct for clean audio output.

Double-check all connections before closing.

2. Close the Front Panel

1. Place the front panel with the mounted speaker and FM board onto the enclosure.
2. Insert the 9V battery into the clip.
3. Use screws to fix it firmly to the main box.
4. Ensure the volume knob and tuning knob rotate freely.

3. Power ON and Test Your FM Radio

Now the exciting part!

1. Turn ON the radio using the SPST switch.
2. Rotate the volume knob to the right to increase the audio level.
3. Use the tuning knob to search for local FM stations.
4. Adjust the antenna for clearer reception if needed.

Your DIY FM Radio Is Now Ready!

1. The radio turns ON smoothly.
2. Stations tune clearly with good antenna alignment.
3. Audio is loud and crisp from the 5W speaker.
4. The MDF enclosure gives it a clean, professional, and beautiful look.

You’ve successfully built a fully functional DIY Sony 1619 FM Radio at home!

Building this DIY FM Radio using the Sony 1619 FM Receiver Kit is not just a fun weekend project—it’s an excellent hands-on learning experience. You explored the basics of electronics, soldering, enclosure making, audio amplification, and FM tuning, all while creating a fully functional radio from scratch.

By crafting your own MDF enclosure, installing the speaker, tuning knobs, switch, and antenna, you transformed a simple kit into a neat and presentable device that looks great and performs even better. The satisfaction of powering it ON, adjusting the volume, and tuning into your favorite local radio stations is truly unmatched.

This project proves that with a few components, basic tools, and some patience, anyone can build a clean, reliable, and great-looking FM radio at home. Whether you’re a student, hobbyist, or DIY enthusiast, this FM Radio is a perfect start to understanding audio electronics and DIY fabrication.

Your radio is now complete—and it works beautifully. Enjoy listening! 🎧📻