[BF38] bought a mid-range miniature drill-press, and discovered that it was just too short for some of his applications. “No problem,” he thought, “I’ll just measure the column and swap it out for a longer one.” It sounds foolproof on paper.
He discovered, after having bought a new 48.3 mm steel column, that the original was 48 mm exactly in diameter. He’d have to make it fit. But how do you bore out a 48 mm diameter hole, keeping it perfectly round, and only increase the diameter by 0.3 mm? A file is out because you’d never get it round. A lathe is out because [BF38] doesn’t have a lathe.
[BF38] ended up making a DIY honing head, which is a gadget that presses (in this case) two pieces of sandpaper evenly against the sides of the hole to be widened. The head in question is a little bit rough — it was made as a learning project, but it looks like it served the purpose admirably.
Here’s a tale that warms our hearts. [Gord] is helping out the local living-history museum by rehabbing a historic woodworking tool that they want to add to their live demo woodshop. It’s a hundred-year-old manual drill press that has seen a ton of use.
There are three things that [Gord] has going for him. First off, the Champion Blower and Forge Co. built them to last. Second, he’s not really working on a deadline; the museum doesn’t need it back until May. And third, [Gord] has the tools he needs to do this right.
After cleaning and blasting [Gord] gets down to the really interesting repairs. First off, it wouldn’t be a drill press if someone hadn’t tried to drill through the table at some point. TIG welding filled it up and some milling brought it back. This same method was used again to make a beautiful custom replacement ACME rod. Throwing in a custom bushing replacement, turned wooden handle, and a several other fabricated parts, and [Gord] had the press working again. Check out the mechanism in the video below that shows the crank action turns the bit and a cam advances it through the work piece.
Continue reading “Rehabbing an Historic Tool from Champion Blower and Forge Co.”
DIY PCBs are the fastest and cheapest way to iteratively prototype circuits, and there’s a lot of great tricks to get the copper layer just the way you want it. But if you’re using through-hole parts, you eventually have to suffer the tedium of drilling a potentially large number of precisely aligned holes. Until now. [Acidbourbon] has built up a very nice semi-automatic PCB drill machine.
Semi-automatic? The CNC machine (with PC-side software) parses the drill file that most PCB design software spits out, and moves an X-Y table under your drill press to just the right spots. The user manually drills the hole and hits enter, and the table scoots off to the next drilling location. All of this is tied together with a simple calibration procedure that figures out where you’ve got the board using two reference drill locations; you initially jog the platform to two reference drill holes, and you’re set.
The CNC conversion of a relatively cheap X-Y table is nicely documented, and the on-board touchscreen and USB interface seem to make driving the machine around painless. Or at least a lot less painful than aligning up and drilling all the holes the old-fashioned way. Everything is open-source, so head on over and check it out. (And while you’re there, don’t miss [Acidbourbon]’s tips and tricks for making PCBs using the toner transfer method.)
Seeing this machine in action, we can’t wait for the fully automatic version.
Continue reading “Semi-Auto PCB Drill Press Makes Drilling Semi-Painless”
Milling machines are nice to have around for precisely drilling holes or removing unwanted material from a part. However, they can be expensive and may not get a lot of use, two reasons why a mill purchase may not make sense for a home shop. [David] didn’t need a mill, he wanted one and he didn’t want to spend a lot of money. He did have an old bench top drill press and a lathe in his shop and thought it would be a good idea to combine them them into a DIY Milling Machine.
The problem with just throwing a milling bit in a drill press and trying to mill metal is that the drill press spindle ball bearings are not made for radial loading. [David] knew this and replaced the stock ball bearings with angular roller bearings. These new bearings would require an axial preload applied to keep the spindle in place. This was done by machining threads into the spindle’s shaft and adding a nut to secure and preload the new angular roller bearings.
[David] did not have an XY Table to donate to the project so he decided to mount the drill press to his lathe and use the lathe axes to move the work piece around underneath the mill. Thick plate steel was welded together to form a hefty bracket that bolted to both the lathe bed and drill press column. And yes, the lathe is still functional and the changeover process is simple. To go from Mill to Lathe; the work piece is removed from the lathe’s cross slide and replaced with the lathe tool holder. That’s it!
Overall, [David] is happy with his conversion. He doesn’t expect his project to be as precise or rigid as a proper milling machine but says he has no problem cutting 1mm deep passes in steel when using a 6mm diameter mill bit.
Drill presses are a staple tool of the typical garage — they aren’t too expensive and are indispensably useful — but have you ever thought of turning it into a spindle sander?
You can buy drum sander kits fairly cheap, but the problem is they’re really difficult to use and really messy too — you’ll have sawdust everywhere in no time. What [Carl’s] done here is created a wood box for his drill press with different size holes for each drum sander bit. By attaching a vacuum cleaner to the box, you can clean up your mess while you’re still doing the work.
Just a note — drill presses aren’t designed to take radial loads like a mill is. If you’re planning on doing some really heavy sanding, adding a bolt through the entire drum sander bit and then coupling it with a fixed bearing inside of your box might be a good idea.
It’s a pretty simple hack, but could save you an additional power tool, and space on your work bench! Have a drill but no drill press? No problem.
Tape decks are fertile hacking ground. In this offering from [Erich] the speed of the motor has been turned into a MIDI instrument. Drive it faster and the pitch rises, slower and it falls. There are all kinds of other magnetic tape hacks around here, this tape delay is a classic.
[Dbever] needed a reason to use a big 7-segment display module. He opened up the drill press at his Hackerspace, Pumping Station One, and added a sensor which shows the RPM of the drill on the display. Hackaday was lucky enough to be invited for a tour of the space last fall.
There’s a lot of hype about 3D printing… and rightly so since it’s the radest; which is even better than being “the most rad”. But if you don’t have access to one that shouldn’t stop you. Here’s an example of making robot parts using polymorph instead of 3D printing (or laser cutting) them.
If you’re living in the east-coast metroplex and are unable to travel to Maker Faire Bay Area this Spring you can still get in on some live hacking. Check out MassHack which takes place the same May weekend but in Boston instead of San Fran.
Blimps; not as cool as quadcopters but orders of magnitude less likely to go down in flames (as it were). Draw some inspiration for your own build from silent_runner. The graceful travel of these lighter-than-air-craft make for an interesting camera platform. Here’s a POV video inside of a church, and some shots from the ground while in the woods. [Thanks Oliver]
We try not to pimp crowd-funding campaigns just for the sake of getting them to the goal. But we hope you’ll agree that the Gamebuino we saw a few months back makes a strong argument for backers. Their Indiegogo for the Arduino-compatible handheld gaming rig is over half-way there after just a couple of days.
[Moogle] wrote in to see if anyone can figure out why his unused electrolytic capacitors are popping. This is the behavior you see in populated caps whose electrolyte dries out. But these are still in his parts bin. Anyone know why they would pop when going unused?
We see a lot of BIOS flashing hacks; but it’s always a handy thing to know about when you get in a bind. Here [Adan] shows us how to reflash a corrupt BIOS using a Tiva C Launchpad board.
Wanting to hack together her own blow gun [Carlyn] scrapped a handheld vacuum cleaner. When she discovered the pump could not easily be converted from suck to blow she made a handheld suction manipulator which picks up paper plates and a few slightly heavier objects.
Unfortunately a drill press is not one of the tools we have in our lair right now. If we did, this tip about using it to help tap threads in a hole would come in really hand.
Retro computing fans will appreciate this Z80 computer build (translated). It’s a fairly large mainboard with plenty of chips, resistors, buttons, and seven segment displays. Excellent. [Thanks Daniel]
We start to drool a little bit when we see a teardown post that shows off a piece of equipment really well. We’ve already reached for a bib to catch the slobber from pawing our way through [David’s] teardown of an HP 6010A bench supply.