Workshop Tools Are Available In First-Class

July 28, 2021 by Bryan Cockfield 12 Comments

Most of dream of having a fully-stocked shop with all of the tools needed to build our projects, at least if we don’t already have such a shop. In the meantime, a lot of us are hacking together our own tools and working on whatever bench space might be available to us. While [Emiel] aka [The Practical Engineer] has an envious shop to work from, his latest project goes to show how repurposing some aircraft-grade equipment can result in a high-quality toolbox for himself, without shelling out for any consumer-level solution. (Video, embedded below.)

The core of his workshop cart build is actually a recycled food service cart from an airline. While the original probably only housed some soft drinks and ice, this one has been kitted out to be much more functional. Since [Emiel] is using this to wheel around his machine shop, he used a CNC machine to cut out slots in black MDF sheets which would hold his drill bits, taps, and other tools. Working with MDF on a CNC machine turned out to not be as simple as he thought, since the MDF would separate and break away unless the CNC tool heads were operated in a specific way.

The build also includes several buckets for other tools, and a custom enclosure for the top of the cart specifically built for his machine tools’ tools to sit while he is working. It’s certainly a more cost-effective solution to a wheeled shop toolbox than buying something off-the-shelf, and a clever repurposing of something which would have otherwise ended up in a landfill. [Emiel] is no stranger to building any tools that he might need, including this custom belt sander built completely from the ground up.

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Tracking Boats And Ships In Real Time At The Same Time

October 22, 2020 by Bryan Cockfield 15 Comments

Software-defined radio came on the hacker scene in a big way less than a decade ago thanks to the discovery that a small USB-based TV tuner dongle could be used for receiving all kinds of radio transmissions. Two popular projects from that era are tracking nearby airplanes and boats in real time. Of course, these projects rely on different frequencies and protocols, but if you live in a major port city like [Ian] then his project that combines both into a single user interface might be of interest.

This project uses an RTL-SDR dongle for the marine traffic portion of the project, but steps up to a FlightAware Pro dongle for receiving telemetry from airplanes. Two separate antennas are needed for this, and all of the information is gathered and handled by a pair of Raspberry Pis. The Pis communicate with various marine and air traffic databases as well as handles the custom user interface that knits both sets of information together. This interface was custom-built from a previous project of his and was repurposed slightly to fit the needs of this one.

This is a great project that goes into a lot of interesting detail about how the web traffic moves and how the UI works, so even if you’re not into software-defined radio it might be worth a look. However, it’s also worth noting that it hasn’t been easier to set up a system like this thanks to the abundance and low price of RTL-SDR dongles and the software tools that make setting them up a breeze.

Airlines Seek Storage For Grounded Fleets Due To COVID-19

August 19, 2020 by Lewin Day 58 Comments

Ask any airline executive what their plans were back in January 2020, and you’d probably get the expected spiel about growing market share and improving returns for shareholders. Of course, the coronovirus pandemic quickly changed all that in the space of just a few months. Borders closed, and worldwide air travel ground to a halt.

Suddenly, the world’s airlines had thousands of planes and quite literally nowhere to go. Obviously, leaving the planes just sitting around in the open wouldn’t do them any good. So what exactly is involved in mothballing a modern airliner?

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Infinite Flying Glider

April 2, 2020 by Bryan Cockfield 5 Comments

If you’ve exhausted your list of electronics projects over the past several weeks of trying to stay at home, it might be time to take a break from all of that and do something off the wall. [PeterSripol] shows us one option by building a few walkalong gliders and trying to get them to fly forever.

Walkalong gliders work by following a small glider, resembling a paper airplane but made from foam, with a large piece of cardboard. The cardboard generates an updraft which allows the glider to remain flying for as long as there’s space for it. [PeterSripol] and his friends try many other techniques to get these tiny gliders, weighing in at around half a gram, to stay aloft for as long as possible, including lighting several dozen tea candles to generate updrafts, using box fans, and other methods.

If you really need some electricity in your projects, the construction of the foam gliders shows a brief build of a hot wire cutting tool using some nichrome wire attached to a piece of wood, and how to assemble the gliders so they are as lightweight as possible. It’s a fun project that’s sure to be at least several hours worth of distraction, or even more if you have a slightly larger foam glider and some spare RC parts.

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Flywheel Stores Energy To Power An Airplane – Eventually

February 13, 2020 by Dan Maloney 7 Comments

Question: Can a flywheel store enough energy to power an airplane? Answer: Yes it can, for certain values of “flywheel” and “airplane.”

About the only person we can think of who would even attempt to build a flywheel-powered airplane is [Tom Stanton]. He’s a great one for off-the-wall ideas that often pay off, like his Coandă effect hovercraft, as well as for ideas that never got far off the ground, or suddenly met it again. For most of the video below, it seems like his flywheel-powered plane is destined to stay firmly in the last category, and indeed, the idea of a massive flywheel taking flight seems counterintuitive. But [Tom] reminds us that since the kinetic energy stored by a flywheel increases as the square of angular velocity, how fast it’s turning is more important than how massive it is. The composite carbon fiber and aluminum flywheel is geared to the propeller of a minimal airplane through 3D-printed bevel gears, and is spun up with an external BLDC motor.

Sadly, the plane never made it very far, no matter how much weight was trimmed. But [Tom] was able to snatch victory from the jaws of defeat by making the propeller the flywheel – he printed a ring connecting the blades of the prop and devised a freewheel clutch to couple it to the motor. The flywheel prop stored enough energy to complete a few respectable flights, as well as suffer a few satisfyingly spectacular disintegrations.

As always, hats off to [Tom] for not being bashful about sharing his failures so we can all learn, and for the persistence to make his ideas take flight.

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How Efficient Can An Airplane Be? The Celera 500L Sets To Find Out

January 22, 2020 by Roger Cheng 83 Comments

One of the current hype trends is the supposedly imminent revolution in air transport. So many companies showing digital renderings and mockups to illustrate their own utopic vision for the future, reaching fevered pitch at events like CES 2020. But aviation has a long history of machinery that turned out to be impractical. Wouldn’t it be great if a company focused their resources on building real aircraft and get real data before cranking up their hype machine? The people at Otto Aviation thought so, and their Celera 500L has reportedly taken to the skies.

If you said “Otto who?” you are not alone. The company has zero PR activity to speak of. Limited internet attention started from aviation fans spotting the Celera 500L under construction at its Southern California airfield. Its unusual exterior appearance and proximity to Hollywood made some dismiss it at first as a movie prop. Anyone with a passing interest in aerospace engineering could immediately see aerodynamics was a priority in this design, its long thin unswept glider-like wings implies the goal is fuel efficiency rather than speed. This was confirmed by internet sleuths uncovering patents filed by people associated with the company.

The patents include very lofty fuel efficiency goals, and industry veterans are skeptical. Fuel is a huge factor in aircraft operating costs where small increases in efficiency translate to big dollars over a plane’s lifetime. It’s hard to believe every other plane maker would deliberately leave so much on the table. There must be far more to the 500L inside that teardrop shaped body, with innovations and potentially making some trade-offs no other company has made. We can see two of them from the outside: the 500L traded off some pilot visibility for aerodynamics, and it has very little ground clearance to absorb the impact of less-than-ideal landings.

It’s certainly possible the ideas leading to this plane will fail to pan out in reality like so many ideas before them. Aerospace engineering is a field littered with debris of concepts that looked great on paper but crashed against a hard and unforgiving reality. But at least Otto Aviation is trying something new by building real hardware to get real data, something well worth recognizing in a sea of hyped up fantasy renderings.

[Photo via SoCal Airshow Review]

The Rotodyne Fails To Take Off

November 9, 2019 by Al Williams 45 Comments

Bacon and eggs, chocolate and peanut butter, salt and pepper; some things just go together. You’d think that a mashup of an airplane and a helicopter would be great, right? The Fairey Rotodyne was just such a thing from the late 1950s and while it looked to be the wave of the future, it never took off — at least, not in the business sense at least. [Mustard] has an excellent video about the machine including some flight footage and explains why it failed to take over the aviation market. You can watch the video below.

While it does look like a helicopter mated with an airplane, it’s actually a bit different. The rotor isn’t normally powered at all. However, it does turn in forward flight and generates about half the lift the plane needs. That explains the stubby wings. The topside rotor has small jets at the tips that can be used during vertical take off, landing, and hovering modes.

For its time, it was fast and efficient, especially compared to contemporary helicopters. This type of plane was known as an autogyro and actually appeared in the 1930s as a safety mechanism since an autogyro can land in an autorotation mode.

According to the video, the noisy tip jets and production delays killed the beast. There was only one prototype built, but there was something we found very attractive about it. There have been, of course, other autogyros. British, German, Japanese, and Russian military have used autogyros at one time or another. The United States Postal Service was known to employ at least one.

Even today, there are about a thousand autogyros used by different military and police organizations. They are cheaper than a helicopter to buy and fly. Sadly, though, it doesn’t look like autogyros will ever become a common sight. Like an airship, they seem like a callback to an earlier time when you have a chance to spot one.

We are always surprised we don’t see more model autogyros. We wonder how they’d be at cutting down trees.

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