1921 Ner-A-Car Motorcycle Reborn With Epic Parts Remanufacture

Most of the rusty parts you need to make a motorcycle.
Most of the rusty parts you need to make a motorcycle.

Nobody ever dismantles a working motorcycle.

About ten years ago [Andy Pugh] took possession of a large box of rusty parts that formed most of what had once been a 1921 Ner-a-Car motorcycle. They languished for several years, until in 2014 he was spurred into action and returned to the bike. What followed was a two-year odyssey of rebuilding, restoration, and parts remanufacture, and since [Andy] is an engineer par excellence and an active member of the LinuxCNC community his blog posts on the subject should be a fascinating read for any hardware hacker with an interest in metalwork.

The Ner-a-Car. By Museumsfotografierer (Own work) [Public domain], via Wikimedia Commons
The Ner-a-Car. By Museumsfotografierer (Own work) [Public domain], via Wikimedia Commons
The Ner-a-Car represents one of those eccentric dead-ends in automotive history. Designed in 1918 by an American, [Carl Neracher], its name is a play on both its designer and its construction and it is unique in that its design is closer to the cars of the era than that of a motorcycle. It has a car-style chassis, an in-line engine, and it was the first motorcycle to be produced with hub-centre steering. The rider sits on it rather than astride it, feet-forward, and the car-style chassis gives it a very low centre of gravity. They were manufactured in slightly different versions in both the USA and the UK, and [Andy]’s machine is an early example from the British production line. Not many Ner-a-Cars have survived and parts availability is non-existent, so his work has also had the unusual effect of satisfying a significant portion of world demand for the parts-bin of an entire marque.

Spinning up a headlight shell
Spinning up a headlight shell

It’s usual for the first link in a Hackaday article to be to a page that encompasses the whole project. In this case when there is so much to see and the build is spread across twelve blog posts and nearly two years the link is to [Andy]’s first post in which he describes the project, sets to work on the chassis, and discovers the bent steering arm that probably caused the bike’s dismantling. He’s listed the posts in the column on the right-hand side of the blog, so you can follow his progress through the entire build. The work involved in remanufacturing the parts is to an extremely high standard, from machining press tools to reproduce 1920s footboard pressings through manufacturing authentic 1920s headlight switchgear and metal-spinning new aluminium headlight shells.

[Andy]’s most recent Ner-a-Car post details his trip to France on the completed bike, and tales of roadside repairs of a suddenly-not-working machine that should be familiar to any owner of a vintage internal combustion engine. But considering that the bike spent many decades as a pile of not much more than scrap metal the fact that it is now capable of a trip to France is nothing short of amazing.

This is the first rebuild of a vintage bike from a box of rusty parts we’ve featured here – indeed it could almost be a retrotechtacular piece in its detailed look at 1920s bike design. These pages have however seen many motorcycle related  hacks over the years. We particularly like this from-scratch engine build and this gas-turbine bike, but it is the emergency motorcycle build in the desert from a Citroën 2CV car that has us most impressed. Please, ride safe, and keep them coming!

Fail Of The Week: Always Check The Fuse

[Tomas] at Umeå Hackerspace in Sweden had some broken audio equipment, including a Sharp CD player/amplifier. What went wrong when he tried to fix it is a fail story from which we can all learn.

The device worked – for about a second after being turned on, before turning itself off. That’s a hopeful sign, time to start debugging. He took the small-signal and logic boards out of the circuit, leaving only power supply and amplifier, and applied the juice.

Magic blue smoke ensued, coming from the amplifier. Lacking a suitable replacement part, that was it for the Sharp.

On closer inspection it emerged that the previous owner had bypassed the power supply fuse with a piece of copper wire, Evidently they had found the fuse to be blowing too often and instead of trying to fix the problem simply shot the messenger.

We have all probably done it at some time or other. In the absence of a replacement fuse we may have guestimated the number of single strands required to take the current, or used a thin strip of foil wrapped around the fuse body. And we’ll all have laughed at that meme about using a spanner or a live round as a fuse.

So if there’s a moral to this story, it’s to always assume that everyone else is as capable as you are of doing such a dodgy fix, and to always check the fuse.

2013-09-05-Hackaday-Fail-tips-tileFail of the Week is a Hackaday column which celebrates failure as a learning tool. Help keep the fun rolling by writing about your own failures and sending us a link to the story — or sending in links to fail write ups you find in your Internet travels.

Tearing Down an IP Camera

So you bring home a shiny new gadget. You plug it into your network, turn it on, and it does… well, whatever it wants. Hopefully, it does what you expect and no more, but there is no guarantee: it could be sending your network traffic to the NSA, MI5 or just the highest bidder. [Jelmer] decided to find out what a new IP camera did, and how easy it was to find out by taking a good poke around inside.

In his write-up of this teardown, he describes how he used Wireshark to see who the camera was talking to over the Interwebs, and how he was able to get root access to the device itself (spoilers: the root password was 1234546). He did this by using the serial interface of the Ralink RT3050 that is the brains of the camera to get in, which provided a nice console when he asked politely. A bit of poking around found the password file, which was all too easily decrypted with John the ripper.

This is basic stuff, but if you’ve never opened up an embedded Linux device and gotten root on it, you absolutely should. And now you’ve got a nicely written lesson in how to do it. Go poke around inside the things you own!

SATA Cable Replaces DC Motor Brushes as Macgyver Looks On

[dmalhar] was digging around in his bins for motors and found one with missing brushes. Being resourceful (and not able to find another motor), he managed to tear apart a SATA cable and form the pins into brushes with just the right amount of spring. Yes, this looks like a cheap motor, but in the moment of necessity availability wins, and this hack is truly commendable. If he had used a paperclip, MacGyver would have been proud, but the SATA cable pins make us proud.

Normally the brushes of DC motors are made with a graphite or some other material which provides a small amount of resistance so that when the motor is spinning the brushes will provide a gradual shift of current from one commutator to the next. Also, the softness of the carbon makes the brush wear down instead of the commutator, and in large motors the brushes are replaceable. In cheap motors the engineers design the brush material around the expected lifetime of the product. In [dmalhar’s] case, the motor just got its lifetime extended by a while.

Repairing a Sony Dream Machine

Have you ever fancied a gadget but been put off by what seems like an excessive price? [leadacid44] did just that back in 2009, in his case the gadget in question was a Sony Dream Machine ICF-CL75iP. It’s an alarm clock radio, albeit a very fancy one featuring an iPod dock, SD card slot, and an electronic photo frame. Back then it was just too expensive, but in 2016 [leadacid44] spotted one on an auction site for pennies, and so snapped it up.

Of course, with something cheap there is so often a catch. In the case of this Dream Machine, it would not keep time — something pretty important in a clock. But rather than throw it on the “Hack later” pile, [leadacid44] decided to investigate, and turned up a surprising culprit. The glue Sony had used to secure the timing crystal in 2009 had become conductive with age, causing the oscillator to stop oscillating. A simple fix involving a bit of glue removal and a touch of resoldering, and the clock was back with us.

This was a very simple repair when the problem was diagnosed, but it tells us something about electronic product design, and about quality control. Sony have spent a very long time building a reputation for quality manufacture, and it is likely the Dream Machine was built with their full attention to detail. It is highly unlikely that the Sony engineers chose their crystal glue in the knowledge it would break down, after all the company is likely to make far more money selling a new TV or phone to a satisfied alarm clock owner than it is by selling them a new alarm clock. Instead it tells us that even Sony with a legendary attention to quality control can be caught out by unexpected component failures, and that as engineers we should always expect the unexpected.

So [leadacid44] has a new alarm clock, and presumably now always wakes up on time. It’s interesting to look at the Dream Machine from another perspective, to compare what was hot in 2009 with what you might see now. The Apple Dock connector for instance, or the full-size SD card. Both of which are now becoming historical curiosities, even though this device is not much more than six years old.

Over the years we’ve featured a lot of clocks, and even the odd clock radio. But this isn’t really about clock radios, and with that out of the way we’ve certainly featured a few Sony hacks.

Upgrading and Desoldering a Fake CPU

[quarterturn] had an old Apple Powerbook 520c sitting around in his junk bin. For the time, it was a great computer but in a more modern light, it could use an upgrade. It can’t run BSD, either: you need an FPU for that, and the 520 used the low-cost, FPU-less version of the 68040 as its main processor. You can buy versions of the 68040 with FPUs direct from China, which means turning this old Powerbook into a BSD powerhouse is just a matter of desoldering and upgrading the CPU. That’s exactly what [quarterturn] did, with an unexpected but not surprising setback.

The motherboard for the Powerbook 500 series was cleverly designed, with daughter cards for the CPU itself and RAM upgrades. After pulling the CPU daughter card from his laptop, [quarterturn] faced his nemesis: a 180-pin QFP 68LC040. Removing the CPU was handled relatively easily by liberal application of ChipQuik. A few quick hits with solder braid and some flux cleaned everything up, and the daughter card was ready for a new CPU.

The new FPU-equipped CPU arrived from China, and after some very careful inspection, soldering, and testing, [quarterturn] had a new CPU for his Powerbook. Once the Powerbook was back up and running, there was a slight problem. The chip was fake. Even though the new CPU was labeled as a 68040, it didn’t have an FPU. People will counterfeit anything, including processors from the early 90s. This means no FPU, no BSD, and [quarterturn] is effectively back to square one.

That doesn’t mean this exercise was a complete loss. [quarterturn] did learn a few things from this experience. You can, in fact, desolder a dense QFP with ChipQuik, and you can solder the same chip with a regular soldering iron. Networking across 20 years of the Macintosh operating system is a mess, and caveat emptor doesn’t translate into Mandarin.

Repairing and Improving Cheap Bench Power Supplies

Cheap benchtop power supplies are generally regarded as pieces of junk around these parts. They can measure well enough under perfect conditions, but when you use them a little bit, they fall over. There’s proof of this in hundreds of EEVblog posts, Amazon reviews, and stories from people who have actually owned these el-cheapo power supplies.

One of the guys who has had a difficult time with these power supplies is [Richard]. He picked up a MPJA 9616PS (or Circuit Specialists CSI3003SM) for a song. It quickly broke, and that means it’s time for a repair video. [Richard] is doing this one better – he has the 3A power supply, that sells for $55. With a stupidly simple modification, he upgraded this power supply to the 5A model that usually sells for $100.

The problem with [Richard]’s broken power supply were voltage and current adjustments knobs. This cheap power supply didn’t use rotary encoders – voltage and current were controlled by a pair of 1k and 10k pots. Replacing these parts cost about $5, and [Richard]’s power supply was back up on its feet.

After poking around inside this power supply, [Richard] noticed two blue trim pots. These trim pots were cranked all the way to the left, and by cranking them all the way to the right, the power supply could output 5 Amps. Yes, the 3A version of this power supply was almost identical to the 5A version, with the only difference being the price. It’s a good repair to a somewhat crappy but serviceable supply, but a great mod that puts a beefier power supply on [Richard]’s desk.

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