Laptop backlight converted from CCFL to LED


[Lee Davison] acquired an Acer laptop that didn’t have a display anymore. He had enough parts on hand to add in an LCD panel and give it a CCFL backlight. But when he started looking for an inverter to drive the backlight he couldn’t find one. What he did have on hand were some smashed screens that had LED backlights and so the CCFL to LED backlight conversion project was born.

He tore into the LED display and found the driver board. Unfortunately he didn’t locate the datasheet for the exact LED driver, but he found one that was similar and was able to trace out the support circuitry on the PCB. This let him cut away the unneeded parts of the board without damaging the driver. He didn’t want to pull out the CCFL tubes until he was sure the LED conversion would work so he tried it out on another smashed panel (where does he come up with all these parts) and it worked great. Once he got everything in place he was very happy with the results. The only drawback to the system is that he doesn’t have the ability to dim the backlight.

Apple MagSafe cord repair


[Tommy Ward] had a big problem with the cord for his laptop power supply. This thing’s not cheap so he figured out a way to fix the frayed cord on his Apple MagSafe. He asserts that the shortened rubber collar on the plug end of the cord is to blame for this type of damage. We think rough use may have something to do with it too, but having had to repair our own feline-damaged power cords we’re not about to start pointing fingers.

To pull off an appropriate fix [Tommy] pries apart the case housing the power converter. This lets him get at the solder connections of the cord. After removing it from the circuit board he clips off the damaged portion of the cable. To reuse the strain relief grommet he drilled out the old portion of wire and insulation, making room for the undamaged cable to pass through, adding a cable tie on the inside to aide in strain relief. The last part of the fix involves gluing everything back together.

If your power supply problems have to do with the computer connector itself there’s a fix for that too.

DVD power supply repair tips


This demonstration fixes the power supply of a DVD player, but the skills transcend this one application. [Alan] walks us through the process of repairing a power supply (translated) on a simple consumer electronics unit.

Obviously this starts by cracking open the dead device and verifying that the culprit is the power supply. [Alan] then removes that board from the chassis and gets down to work with a visual inspection. He’s got several images which illustrate things to look for; blistered electrolytic capacitors, cracked solder joins, scorch marks, etc. In his case there’s obviously a burnt out fuse, but that merely protects the hardware from further damage, it’s not the cause. Next he examines the diodes of the bridge rectifier. These need to be removed from the system to do so, which he accomplishes by clipping one end of each as seen above. He found that two diodes on one side of the bridge had broken down. After replacing them he tries a new fuse which immediately burns out. But a quick swap of the capacitors and he gets the thing back up and running.

We perk up every time we see this type of repair hack. We figure if we can build our own hobby electronics we should be able to fix the cheap devices like this one.

Epson projector LED mod


Projector bulbs can be incredibly expensive to replace. Sometimes it’s more cost efficient to just buy a whole new projector instead of a new bulb. [Shawn] recently found a nice deal on an ‘as is’ Epson EMP-S4 on eBay and decided to take a chance. He assumed it probably worked with the exception of the missing lamp the seller mentioned. His suspicions were correct, and one custom LED mod later, his projector was up and rolling.

Without a stock lamp installed, the projector would give an error message and shut itself off. So, the first step was to wire up a little bypass. Once that was taken care of, [Shawn] installed a 30W 2000 lumen LED and custom fit an old Pentium CPU heatsink to keep the LEDs temperature down. He also wired up the heatsink fan in parallel with the stock exhaust fan for good measure.  Optical lenses help focus the light, and some custom wiring makes the LED turn on and off just like the stock lamp would.

In the end, his first experiment was a success, but [Shawn] wants to try an 8000 lumen 100W LED to make it about as bright as the stock lamp was. Check out a little video walkthrough after the break.

[Thanks Shawn]

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Heat your house with propane (but not in the way you’re thinking)


[Ralph Doncaster] has a geothermal heat pump which is responsible for providing heat for his home. He’s been looking into some hacks that would make it more efficient and decided that the freon (R-22) needed to be tweaked. Some would say the stuff is bad for the environment, so he decided to go a different route. He replaced the Freon with propane, using this rig to make the fuel-grade propane more like cooling-grade propane called r-290.

He purchased the gauge set which is used whenever a technician services an A/C system (but you can also see it in this other A/C propane hack). That’s important because it’s responsible for making sure the old coolant is recaptured (his hose failure nixed this part of the plan) and the new coolant goes where it should at the correct pressure. But before dumping in propane from the local hardware store he needs to dry it out. Fuel-grade propane can have moisture in it, which can be bad for the cooling system. He bought a drier device, the grey bulb seen above, and soldered it on one end to a propane torch fitting and to a valve connection on the other. Now he could remove moisture as he pressurized the system.

Everything is working again, and the cooling side of the system gets much colder. He plans to do more testing as time goes by.

Repairing broken injection molded parts with a 3D printer


The value of a 3D printer is obvious for people who hack hardware as a hobby. But this repair project should drive home their usefulness for the commoner. [James Bruton] used a 3D printer to recreate a hopelessly broken injection molded plastic part. This is a suction cup mounting bracket for a Tom Tom GPS module. The sphere which makes it adjustable had broken off of the column holding it. For 100% of non-hacking consumers that’s the end of this item. We can’t see a fix that would restore the strength of the original part.

The replacement starts by measuring the broken part with precision calipers. [James] then grabbed a copy of 123D, which is free software. He starts by modeling the sphere, then builds up the support column and the base with a cut-out. It’s obvious he’s already very familiar with the software, but even the uninitiated should be able to get this done pretty quickly. After slicing the design for the 3D printer he finds the part will be ready in about 11 minutes. The first prototype is a bit too small (the ball requires close tolerances to work well). He spins up a second version which is a bit large and uneven. A few minutes of filing leaves him with a smooth sphere which replaces the original part beautifully!

You can see the entire design, print, and assembly process in the clip after the break.

[Read more...]

Hacking the International Space Station with a toothbrush


[Douglas Adams] will tell you not to forget your towel when it comes to space travel. But NASA may start mandating that astronauts always carry a toothbrush. That’s because when a recent repair on a critical International Space Station component went wrong it was a toothbrush hack that saved the day.

The culprit here is a bolt that wouldn’t re-seat after replacing a power transfer module that routes electricity from solar cells to the station’s electrical systems. About how many times have you had trouble with bolt threads? Now put yourself in a space suit in orbit for eight hours trying to get the thing to work. Yikes!

Just like in the movies there was a team of engineers at the ground center which gathered all the supplies available in the ISS. They figured out that metal shavings in the threaded hole needed to be cleaned out and the area lubed for the bolt. One of the two types of tooth brushes on hand would work for the lube, but needed to be stiffened. There was also a brush for cleaning the threads which was made out of a jumper cable. The images seen above are the step-by-step instructions the team uploaded to the astronauts who reproduced their hacked hardware to complete the repairs.

[Thanks G Mob]