Adding line-in to Wards Airline GEN3996 boombox

Superduper

Member (SA)
So Melly owns this fine example of the Montgomery Wards Airline GEN-3996 boombox.
But........... it has NO line-in, so NO aux playback feature. :dunce: :dunce:

We can fix that. We have the technology. So you know what comes next, right?

Here we go.

FIRST, here is the side panel where the line-in jack will be installed, right below the PHONE jack.


Here is the backside of the I/O panel where the jack will be installed.


The yellow and green wires will be removed from the connector (which plugs into the tuner). These wires terminate at the amp. New color correct yellow/green wires with new connector matching crimp connectors will be installed into the connector for a factory complete appearance. The new wires will go to the jack, which then returns to the amp through the old wires. Since the old wires are too short, the pigtailed ends (with connectors) will be inserted into new molex connectors with matching headers to extend the wires.


Here are the pigtailed amp wires. No wires were [strike]harmed[/strike], err cut in this retrofit project, although a new ground wire will be soldered onto the bottom solder pad of the amp where the wire array is located.


Newly installed jack on the left hand side, with the green/yellow wires


A place for everything, and everything in it's place. Ahh, just how I like it. Who wants to tell me that the install doesn't look 100% factory?


New jack installed. What it looks like. A handheld label printer would be real handy right about now to label the new line-in jack.


ALL DONE.


WATCH IT IN ACTION:
[youtube]puAClZKN5nA[/youtube]
 

mellymelsr

Member (SA)
Sep 11, 2009
2,185
27
48
56
Northern Cali
O.M.G. :w00t: ...fantastic work Norm! ...and I'm not saying that just because it's mine, but I am glad it is mine... :-D ... Those are some really nice L.E.D's. As usual your work is second to none. Everytime I see one of your projects I am amazed by your talent. I cannot thank you enough Norm...simply amazing work.

Just so everyone knows when I got this boombox it had a handful of issues. There was an awful electrical smell and humming noise when you plugged it in, the aux input (if you want to call it that) didn't work, the L.E.D's had a mind of there own and weren't very bright, and the radio stations were not tuning in clear stereo. In one fell swoop, Norm fixed all of these issues and added an aux input without a service manual. I am just thankful, not only to have someone like Norm as a friend, but that he shares his gift and takes many of these boomboxes and makes them better than they ever were. So Norm.... :thankyou: ...so very, very, very, very much.
 

JLF

Member (SA)
May 6, 2009
197
0
16
54
Pacific Northwest
Awesome mod!

So many killer boxes Ive owned over the years havent had this feature. Crazy.

You could just about sell this mod as a kit on ebay!
 

Lasonic TRC-920

Moderator
Feb 16, 2010
14,125
82
48
55
Naples, Italy
mellymelsr said:
Lasonic TRC-920 said:
I wish I was rich and could hire you full time! :w00t:

Top Notch work as always Norm!

Nice radio Melly :yes:
Thanks Chris...I am lucky enough to live only 30 minutes away from Norm... :-D
Your a lucky man to have Norm on the staff :lol:

More importantly, there is no shipping radio's to him for repair and risking them getting trashed. Norm and I have spoken about some projects, but I'm too scared they might get trashed....

I might take a drive up in the spring. We'll see. If so, would be great to meet you as well....
 

blu_fuz

Moderator
Staff member
Jun 3, 2009
10,666
154
63
40
WI
Ahhhh, I was wondering the same thing why he didn't use the aux jacks...... Looks factory for sure.
 

mellymelsr

Member (SA)
Sep 11, 2009
2,185
27
48
56
Northern Cali
blu_fuz said:
Ahhhh, I was wondering the same thing why he didn't use the aux jacks...... Looks factory for sure.
The factory aux jacks are recording input jacks only...no sound comes through the speakers. He added a separate jack to avoid any chopping or cutting of factory wires. I am not sure why these inputs were designed this way...seems like a waste, thank goodness I have a friend like Norm... :-D
 

mellymelsr

Member (SA)
Sep 11, 2009
2,185
27
48
56
Northern Cali
Lasonic TRC-920 said:
mellymelsr said:
Lasonic TRC-920 said:
I wish I was rich and could hire you full time! :w00t:

Top Notch work as always Norm!

Nice radio Melly :yes:
Thanks Chris...I am lucky enough to live only 30 minutes away from Norm... :-D
Your a lucky man to have Norm on the staff :lol:

More importantly, there is no shipping radio's to him for repair and risking them getting trashed. Norm and I have spoken about some projects, but I'm too scared they might get trashed....

I might take a drive up in the spring. We'll see. If so, would be great to meet you as well....
...I would be happy to stop by for a mini-Cali-boombox meet.... :thumbsup: ...just let me know when and I'm there.
 

Maxx134

Member (SA)
Mar 26, 2012
103
0
16
NYC USA
OMG that box looks sooo beautiful! wow I never knew so many beautiful boxes existed before so its really great to see this one restored :)

Hey "Lasonic TRC-920" is that a real box in your profile pic, or photoshoped? :)
 

AE_Stereo

Member (SA)
Apr 24, 2012
726
104
43
Abu Dhabi, UAE
mellymelsr said:
blu_fuz said:
Ahhhh, I was wondering the same thing why he didn't use the aux jacks...... Looks factory for sure.
The factory aux jacks are recording input jacks only...no sound comes through the speakers. He added a separate jack to avoid any chopping or cutting of factory wires. I am not sure why these inputs were designed this way...seems like a waste, thank goodness I have a friend like Norm... :-D
With this deck there was no need of fixing an extra Line-In jack. The Line in will work with the Record button pressed on - right?

You only need to find a plug that will go into the Remote Socket along with mics (roughly half the size of a 3.5mm Headphone jack, but in mono).
When the plug pin is inserted into the Remote socket, the power to the motor is cut off. (In fact the power to the motor goes through the pin now. If you short the pin terminals, motor will get power).

So with the pin inserted into the remote, plug the external source into the built in Line-In RCA sockets. Press Pause on first and then Record+Play buttons to switch on the stereo. (You may have to open the cassette door and release the Erase Tab protection switch or insert a cassette with Leader tape at the visible position to press the Record button).

There is nothing to wear out now. I don't think there is any other damage while keeping the play button pressed along with Pause On and motor not running. A cassette deck is designed to work so for 30 years (that is why we are able to talk about it now).
 

T-STER

Member (SA)
Jul 14, 2014
2,246
73
48
UK
peksy24 said:
I love that your very first post was not something like an introduction, or a poignant statement or a picture of a cool box, it was to say "nice" on a five year old post. Way to go great entrance :sadno: