Helix Turning Tool Born From Necessity

helix turning tool

Sometimes while working on a project there comes a point where a specialized tool is needed. That necessary tool may or may not even exist. While [Fabien] was working on his DNA Lamp project he needed to bend a copper wire into a helical shape. Every one of us has wrapped a wire around a pencil and made a little springy thing at some point. While the diameter may have been constant, the turn spacing certainly was not. [Fabien] came up with a simple gizmo to solve that problem.

The tool utilizes an 8mm rod that will ensure the ID of the helix is indeed 8mm. We’ve already discussed that was the easy part. To make certain the turn spacing is not only consistent but also of the correct amount, a wooden frame is used. The frame has holes in it to allow the 8mm rod to pass through. Adjacent to those rod holes are much smaller holes just a bit larger than the copper wire that will become the helix. These holes are drilled at an angle to produce the correct turn spacing. [Fabien] figured out the correct angle by taking the desired turn spacing distance, helix diameter and wire diameter and plopping it in this formula:

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Bending materials with a simple hot wire forming tool


Regular reader [RoadWarrior222] has watched as we’ve featured several projects that show how to bend acrylic. But so far he hasn’t seen us cover his favorite technique developed by [Dale A. Heatherington] which uses a hot wire forming tool to make precise bends. The tool is simple to use plus it’s cheap and easy to build. It’s a great choice if you don’t have a heat gun, and it may be possible to make cleaner bends than other techniques.

The business end of the bending tool is the red-hot Nichrome wire running through the aluminum channel. That channel is used to protect the MDF and act as a spacer so that the wire doesn’t touch the acrylic. On the near side the wire is anchored with a screw, but on the far end it is kept taught by including a spring. The wire heats up as it is connected to a 12V battery, but since the heating is cause by the wire’s resistance it will only get red-hot in between the alligator clips providing power. To make sure your bends will be perpendicular to the edge of the acrylic there’s an aluminum guide strip on one side of the MDF platform.

You can salvage Nichrome wire from an old hair dryer. If you have any left over it’s great for other projects like building a CNC hot-wire cutter.

8 bit digital sampler kit, bendable too

No, it’s not flexible, its bendable. As in, you can hack it to sound different by connecting parts in random ways.  “Where’s the Party At?”, or “WTPA” for short is a bendable 8 bit sampler made by [Todd Bailey]. Still curious what it is? Watch his video showing it in action. The video is huge, 93Megs, so be patient. The overall attitude of this project is built around hacking. Consider this quote from his page ” I’ve got lots of things to poke, bend, illuminate, invoke, distrust, regulate, and otherwise get jiggy with. It’s like being 15 at the mall again! “.   Sounds like fun to us.

[via Create Digital Music]

Fun with Barbie karaoke machines

[Peter Edwards] at Casper Electronics built a modular synth and integrated it with the Barbie karaoke machines we saw at Notacon last April. The complete unit consists of 25 modules which are wired together using banana cables. He’s using this homebrew step sequencer to control the bent karaoke machines which then feed into the rest of the synthesizer. If you’d like to bend your own barbie karaoke machine, [Peter] was kind enough to post schematics and instructions for his bends.