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 Post subject: Zenith Royal 500 cabinet repair
PostPosted: Sep Tue 21, 2021 3:21 pm 
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Joined: Sep Fri 14, 2018 11:18 pm
Posts: 81
Location: Livorno, Italy
Hi, I bought this Royal 500B initially aiming to use it as a parts radio, but it turned out to be nice enough to be salvaged. The most significant damage externally is yellow-circled in one of the attached photograph. Advice needed about whether or not it could be worth trying to repair it and (if yes) about best product/tecnique to use.
Thanks in advance for your feedbacks.
Regards
Daniele


Attachments:
IMG_20210916_163219.jpg
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 Post subject: Re: Zenith Royal 500 cabinet repair
PostPosted: Sep Tue 21, 2021 3:54 pm 
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Joined: Oct Mon 26, 2009 10:02 pm
Posts: 7168
Location: Indianapolis, IN
That radio looks like it will clean up very well---definitely not a parts set !

I wouldn't be concerned about that small chip---not that noticeable unless you are viewing from top... Nylon does not glue well and the material is thin at that point.

Be sure and post a "complete" picture once clean !

John


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 Post subject: Re: Zenith Royal 500 cabinet repair
PostPosted: Sep Tue 21, 2021 4:01 pm 
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Joined: Sep Fri 14, 2018 11:18 pm
Posts: 81
Location: Livorno, Italy
Thanks John, in fact I too was worried about the risk of making things worse without a real need.


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 Post subject: Re: Zenith Royal 500 cabinet repair
PostPosted: Sep Tue 21, 2021 4:19 pm 
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Joined: Oct Mon 26, 2009 10:02 pm
Posts: 7168
Location: Indianapolis, IN
Daniele,

Yes, it would be a risk and think you'd still see evidence afterward---but maybe someone else will have a suggestion...

That should be a beauty once carefully detail cleaned. Looks well cared for other than the dust and finger marks...

John


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 Post subject: Re: Zenith Royal 500 cabinet repair
PostPosted: Sep Tue 21, 2021 5:26 pm 
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Joined: Aug Mon 16, 2021 3:25 am
Posts: 38
Daniele,

How does this radio work? Sometimes these old Zenith 500's will play very well with original capacitors & transistors....and
sometimes they won't. I have several of these in my collection that play strong with all original parts.

If you need to remove chassis, use caution (and patience) when removing knobs. I use (4) wooden coffee stirrers
positioned at the N-S-E-W positions and slowly force them inward. The soft wood will not leave scratches and provides
an even "lift". Be real careful with the clear tuning "skirt" as they can be brittle and crack easily.

I have also bought "parts" radios and found them to be too good to part-out.

The small chip is a minor blemish IMO. Any repair attempt or filler will most likely be just as noticeable. If this radio were
mine, I wouldn't bother trying to correct the chipped cabinet. Sometimes you get lucky and find the chipped-off piece in the
radio. I have reattached a perfectly fitting piece using Super-Glue Gel from the inside, leaving an almost invisible seam on the
outside.

Enjoy your Zenith!

Jeff


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 Post subject: Re: Zenith Royal 500 cabinet repair
PostPosted: Sep Tue 21, 2021 5:46 pm 
Member

Joined: Sep Fri 14, 2018 11:18 pm
Posts: 81
Location: Livorno, Italy
1N770 wrote:
Daniele,

How does this radio work? Sometimes these old Zenith 500's will play very well with original capacitors & transistors....and
sometimes they won't. I have several of these in my collection that play strong with all original parts.

If you need to remove chassis, use caution (and patience) when removing knobs. I use (4) wooden coffee stirrers
positioned at the N-S-E-W positions and slowly force them inward. The soft wood will not leave scratches and provides
an even "lift". Be real careful with the clear tuning "skirt" as they can be brittle and crack easily.

I have also bought "parts" radios and found them to be too good to part-out.

The small chip is a minor blemish IMO. Any repair attempt or filler will most likely be just as noticeable. If this radio were
mine, I wouldn't bother trying to correct the chipped cabinet. Sometimes you get lucky and find the chipped-off piece in the
radio. I have reattached a perfectly fitting piece using Super-Glue Gel from the inside, leaving an almost invisible seam on the
outside.

Enjoy your Zenith!

Jeff


Thanks so much for your tips, Jeff. I really appreciate them.
Daniele


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 Post subject: Re: Zenith Royal 500 cabinet repair
PostPosted: Sep Tue 21, 2021 6:38 pm 
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Joined: May Mon 25, 2020 7:37 pm
Posts: 955
Location: Greater Boston, MA
I've repaired chips like that--albeit in thicker material--using epoxy putty, sanded and painted to match. Not invisible, but much better than a hole.


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 Post subject: Re: Zenith Royal 500 cabinet repair
PostPosted: Sep Tue 21, 2021 7:17 pm 
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Joined: Aug Tue 31, 2021 5:50 pm
Posts: 34
Picked up a Mitsubishi am/sw transistor radio marketed by Continental. This was for spares due to it’s ‘not workin’ damaged case description for $5.00. The other version turned out to be in perfect cosmetic condition and only required tired cap replacements. So now I have two! Also the handle is the SW antenna as well as stand and carry handle. The Westinghouse Jewel for scale.

The case was really damaged and of course the guts needed caps, corrosion cleaning, resoldering …

However lets look at the case. Many missing bits of plastic, broken screw posts, obviously dropped at some point.

The plastic was an automotive product for recreating plastic parts (two part epoxy) found on modern cars such as plastic screw posts for headlamps. Standard primer and for plastic enamel paint. If you have an airbrush you could get away without a full repaint. Much easier to create and match a gloss black paint to cover the plastic repair. Also this plastic repair is STRONG. I purposely tried to break the joint after application just to test its strength. It felt like the case would crack but not at the repair seam. Very happy. Now I will try to find the product name and post.

The first set of photos show the broken bits of the case followed by the plastic epoxy, sanding, priming, sanding, more filler, sanding …. You will note the filler requires colour. I elected to paint the main bezel which had the cracks and chips (the lighter blue). The back shell was complete so only required a fine sanding and plastic polish. The reverse painted dial had a crack (actually completely separated corner) which was put in positioned, glued, sanded and plastic polished. Still don’t know how to make a clear plastic repair invisible ;-)

And the final outcome which has had the electronic faults addressed as well as the cosmetics.


Attachments:
File comment: Missing chips 1
B6F84BCF-4A37-44FC-9CB9-42DD4371E14C.png
B6F84BCF-4A37-44FC-9CB9-42DD4371E14C.png [ 492.28 KiB | Viewed 396 times ]
File comment: Cracks and chips 2
D027FCC9-16AA-4A09-BB11-2BE7E439C56F.png
D027FCC9-16AA-4A09-BB11-2BE7E439C56F.png [ 433.84 KiB | Viewed 396 times ]
File comment: Filler (this took awhile with application followed by sanding and repeat until my OCD is satisfied.
AE0030F3-2098-4483-8E7B-6340437558FD.jpeg
AE0030F3-2098-4483-8E7B-6340437558FD.jpeg [ 1.65 MiB | Viewed 396 times ]
File comment: Chips and cracks on other side filled.
7FC79607-EED8-49BA-B96B-CAFAD08314ED.jpeg
7FC79607-EED8-49BA-B96B-CAFAD08314ED.jpeg [ 1.28 MiB | Viewed 396 times ]
File comment: Primed for sanding.
54D27DBF-9B14-4015-BDA6-0CEFB2DCDA2E.jpeg
54D27DBF-9B14-4015-BDA6-0CEFB2DCDA2E.jpeg [ 1.32 MiB | Viewed 396 times ]
File comment: Other views of repaired and primed radio; in total 5 large missing chips and cracks propagating from the chips.
2FE5CA35-4BD1-4AEC-B514-0A5A24171CA2.jpeg
2FE5CA35-4BD1-4AEC-B514-0A5A24171CA2.jpeg [ 1.33 MiB | Viewed 396 times ]
File comment: Final
F5DF72F0-167E-4005-AFA3-22E13048E043.jpeg
F5DF72F0-167E-4005-AFA3-22E13048E043.jpeg [ 715.7 KiB | Viewed 396 times ]
3031A611-DE69-420C-97F6-AC7973405DAF.jpeg
3031A611-DE69-420C-97F6-AC7973405DAF.jpeg [ 659.71 KiB | Viewed 396 times ]
FC3759E4-4174-4648-BF63-0E65C3424995.jpeg
FC3759E4-4174-4648-BF63-0E65C3424995.jpeg [ 627.79 KiB | Viewed 396 times ]
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 Post subject: Re: Zenith Royal 500 cabinet repair
PostPosted: Sep Wed 22, 2021 12:47 am 
Member

Joined: Dec Wed 16, 2015 10:31 pm
Posts: 334
Location: Toronto ON
Sorry to hijack this thread, but I recently pulled the very same radio - Silver branded, out of my parts bin. I had acquired it as a parts unit due to the condition. It must have been dropped onto one end as the handle pivot was completely broken away. It also looked like the volume knob had broken in the process as it was missing and a previous owner had drilled a hole to turn the volume control with a screwdriver. The battery compartment was also in rough shape. All of the springs had fallen out of one end as a spill had caused the plastic to crumble. I was about to begin parting it out when I thought I should power it up to see if it had any life in it. I was astonished to find it was working perfectly with all its original components. The reception on shortwave was amazing and even longwave was bringing in several local NDB's. I decided to patch it up with as many chips as I could find, and some hobby styrene. I found a volume knob that just fit, so now I have a 'runner'. I don't anticipate restoring it any further - too many higher priority restos waiting to be done.
Regarding chips in a Royal 500, I have had good luck lately repairing chips in Emerson 888's, but don't know if the same procedure would work with the Zenith nylon.

Joe


Attachments:
Silver SW.JPG
Silver SW.JPG [ 419.04 KiB | Viewed 365 times ]
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 Post subject: Re: Zenith Royal 500 cabinet repair
PostPosted: Sep Wed 22, 2021 3:10 am 
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User avatar

Joined: Jan Thu 01, 1970 1:00 am
Posts: 39555
Location: SoCal, 91387
The chip is small enough, and located in a not too noticeable area of the cabinet, that it's kinda a tossup as to whether to leave it as-is, or attempt a repair. Since there doesn't seem to be any posts on repairing Nylon that have been mentioned, all you can do is try it.

I have patched several sets using Plas-T-Pair, which is made for plastic;
https://www.amazon.com/RAWN-Plas-T-Pair/dp/B00CAJBHRE

My method is to put a piece of Scotch Tape on the outside of the cabinet, over the chipped out area, and then another smaller piece with it's sticky side toward the first piece, so there is a rigid, yet smooth area. You would apply some of the powder into the cavity, then add some liquid, and smooth over it with a flathead screwdriver. It doesn't take long to dry. Afterward, gently sand as or if necessary, and paint with enamel.

_________________
\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\He Who Dies With The Most Radios Wins/////////////////////////


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 Post subject: Re: Zenith Royal 500 cabinet repair
PostPosted: Sep Wed 22, 2021 8:33 am 
Member

Joined: Sep Fri 14, 2018 11:18 pm
Posts: 81
Location: Livorno, Italy
The above is a detailed and viable procedure, thanks.
However I'm worried enough about the risk of a failure that I'm thinking I will stay with the chip for now.
Best regards
Daniele


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