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How to make a glass scale - Printable Version

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How to make a glass scale - Vlad95 - 07-04-2026

All radio receivers, from the very beginning, have been indispensable without a dial. This component was, in principle, required to be present in one form or another in every radio. Of course, we're talking about ordinary household appliances, not radios in general, which could include quite specific devices. The simplest example would be radio receivers with fixed channels.
For us in this topic, we're interested in how to restore or re-fabricate a dial for a radio being restored.
This topic is especially relevant for glass dials. This is because they are one of the most common types of dials. Secondly, in a good third, if not half, of the cases, over the long life of an antique radio, this most fragile and vulnerable part often ends up, at best, simply peeling from age, or at worst, cracked or shattered.
While cutting a glass blank to the required size isn't too difficult, applying a highly detailed, often colorful, design to it is a very challenging task for a homebrew project.
This task is usually accomplished using silkscreen printing, and you can find a specialist to fulfill this request. The problem is that this method is designed for mass production, while a one-off order would be prohibitively expensive.
I'll attempt to describe in detail two manufacturing methods for glass scales here.
The first is simpler, using color inkjet printing on transparent self-adhesive film. The only drawback is the need for this very film.
The second is more complex, based on thermal transfer of a laser-printed image. However, it doesn't require any specific materials.
Both methods, however, require exceptional care and meticulous attention to detail.

For now, I'll describe the first method. The second stalled due to the poor performance (smearing) of my color laser printer. As soon as I get it up and running, I'll return to this topic.

RE: How to make a glass scale - Vlad95 - 07-04-2026

I'm currently working on one of the first vacuum-tube portable radios of the USSR, the "Dorogny." Unfortunately, it had no dial at all, lost in the mists of time.
This is a picture of it from the internet.

[Image: https://radionostalgia.ca/My_collection/Build_Scales/Img/Dorojniy-2.jpg]

RE: How to make a glass scale - Vlad95 - 07-04-2026

Fortunately, the scale drawing for this radio was found online many years ago and was thoughtfully stashed away in the computer's memory.
The drawing was straightened, calibrated for printing at the correct size, and mirrored in accordance with the required technology.


[Image: https://radionostalgia.ca/My_collection/Build_Scales/Img/scale-11.jpg]

[Image: https://radionostalgia.ca/My_collection/Build_Scales/Img/scale-12.jpg]

RE: How to make a glass scale - Vlad95 - 07-04-2026

Glass blanks were cut out. The scale of a Nov radio receiver, a virtually identical clone of the Dorozhny radio, served as a template.
I highly recommend sanding the ends of the blanks with a diamond stone to avoid injury during the subsequent meticulous work.

[Image: https://radionostalgia.ca/My_collection/Build_Scales/Img/scale-01.jpg]

RE: How to make a glass scale - Vlad95 - 07-04-2026

Here is a package of transparent sheets for printing self-adhesive stickers on an inkjet printer.

[Image: https://radionostalgia.ca/My_collection/Build_Scales/Img/scale-02.jpg]

RE: How to make a glass scale - Vlad95 - 07-04-2026

The scale is printed. It has a cutout to make the pointer visible. The film, although transparent, is matte, making it difficult to see anything that isn't directly adjacent to it.

[Image: https://radionostalgia.ca/My_collection/Build_Scales/Img/scale-08.jpg]

RE: How to make a glass scale - Vlad95 - 07-04-2026

The first test of the scale revealed that the printed image was not very durable and smudged easily.

[Image: https://radionostalgia.ca/My_collection/Build_Scales/Img/scale-09.jpg]

Therefore, a protective sticker was applied to the printed side, in which a reticle window was also cut.

[Image: https://radionostalgia.ca/My_collection/Build_Scales/Img/scale-05.jpg]

[Image: https://radionostalgia.ca/My_collection/Build_Scales/Img/scale-06.jpg]

RE: How to make a glass scale - Vlad95 - 07-04-2026

The glass blank is thoroughly washed and degreased with alcohol. The protective paper is removed, and the design is glued to the glass. The excess is trimmed off, and the scale is ready.

[Image: https://radionostalgia.ca/My_collection/Build_Scales/Img/scale-07.jpg]

RE: How to make a glass scale - Vlad95 - 07-04-2026

The body of the radio receiver with an installed scale.

[Image: https://radionostalgia.ca/My_collection/Build_Scales/Img/Dorojniy-1.jpg]

RE: How to make a glass scale - MrFixr55 - 07-04-2026

NICE!!! Great job, Vlad!! Wish there was a pdf of the dial scale for my Telefunken Allegro. Glass is broken but glued back together. However, the break is noticeable.

RE: How to make a glass scale - Vlad95 - 07-04-2026

Hello, MrFixr55,
I think in your case, you can create an image file yourself from the existing glass. This can be a problem if the glass is lost, as in my case. However, if the original glass is still intact, you can do it. Remove the glass from your radio, take a photo of the existing glass in the highest possible quality. Then, use a graphics editor to correct cracks and other image errors.
In my case, I also had to correct image defects and adjust the size. In the attached photo of the finished scale, you can see that the glass is slightly wider than the sticker and has some defects. This happened because the image from the internet was 108 mm by 28 mm, whereas the actual size should have been 108 mm by 30 mm. Therefore, the final scale was only corrected on the third attempt.

On my website you will find a number of scale drawings and other graphic materials - Scales

RE: How to make a glass scale - radiorich - 07-04-2026

Hello Vlad,
Wow, that takes a lot of patience to do, and it looks great! I’ve never attempted anything like that before.

Sincerely Richard

RE: How to make a glass scale - Joe Rossi - 07-05-2026

With Vlad's permission, I would recommend this post be placed in the "Important Threads" section of the "Other Radios/Phonographs" Category.  Vlad this is an amazing post Icon_thumbup !  Joe

RE: How to make a glass scale - radiorich - 07-05-2026

hello Joe,
I too agree great idea !
Sincerely richard