Hackaday Links: February 16, 2014

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[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.

Drilling Custom Standoffs

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Every electronics project of sufficient complexity needs standoffs – little plastic or metal cylinders – to mount boards to one another. Keeping hundreds of little plastic trinkets around doesn’t really fit with the hacker mentality, though: it would be far simpler to keep some Delrin rod stock around to drill and cut standoffs as needed. [HomeCSP] created a device to do just that, allowing him to turn 1/4″ Delrin rod stock into any size standoff he needs.

Before building this device, [HomeCSP] was taking plastic rods to the drill press fitted with a very tiny drill bit for a #2 screw. The problems with that technique should be evident to anyone. The new solution uses an old cordless drill and a 6 inch piece of linear rail, effectively turning some bits of scrap into a horizontal drill press with a stationary bit.

The end result is a machine that can bore a hole straight down a 1/4″ rod. With a box of screws these homebrew plastic rods are much cheaper than off-the-shelf parts and can be made in any length desired.

Hackaday Links: June 22, 2012

For when you want something huge machined

Turn your volume down for this video. It’s the HSM-Modal CNC mill carving a full-sized car out of styrofoam, applying clay to the foam core, and machining the clay at 50 meters per minute. Yes, we’ve seen this machine before, but never in action. It only took a little over 24 hours to make this full-size model car.

Microscope into a drill press

If you need to drill some PCBs, [wotboa] has a neat build for you. He built a micro drill press out of a microscope. It’s a damn good idea if you can find a quality microscope base; those things usually have exceptionally high precision. The ‘hack’ part is a $7 Harbor Freight rotary tool, some PVC pipe, and a PWM control for the motor – home-made, natch.

I’m telling you, they need to get [River] out of the library. Work on it [Moffat].

[Alan] made a TARDIS book case, and he decided to share the plans with us. Just the build to combat the severe lack of woodworking and Whovian stuff on Hackaday. Vashta Nerada hopefully not included.

Money can’t buy happiness, but you sure can sell it

[Greg] sent in some info on Disney’s ‘glow with the show’ hats they sell at the California Adventure park. For $25, you get a hat with RGB LEDs in the mouse ears that synchronize with the World of Color show every night. There’s a better description of the hats here, but we’re thinking these are very similar to the Coldplay Xylobands we saw at this year’s Grammys. Anyone want to tear some mouse ears apart?

An exceptionally low-tech radio telescope

[Impulse405] found a poor man’s radio telescope on Instructables and decided to share it with us. [Z0rb] found a 10-foot dish in the garbage and quickly absconded with this retro hardware. After adding a power supply and a meter-based total power receiver, [Z0rb] had a radio telescope that covered wavelengths from 850 to 2200 MHz.

Turning a rotary tool into a PCB drill press

Drilling holes in PCBs is nearly always an exercise in compromise; the holes are small, precision is paramount, and the common solutions, such as a Dremel drill press, aren’t of the highest quality. In a quest to find the best way to drill holes in PCBs, [reboots] even went so far as to get a pneumatic dental drill, but nothing short of a high-quality micro drill press would do. Not wanting to spend hundreds of dollars to drill a few holes, [reboots] did the sensible thing and made one from scratch.

[reboots] ended up buying a Proxxon Micromot 50 after reading the consistently good reviews around the Internet. To use this rotary tool as a drill press required more work, though. Two precision steel rods from a dot matrix printer were salvaged and pieces of aluminum C-channel and small bearings were bolted together into a very high-precision drill press. Only hand tools were used to build this drill press, and the results are amazing.

[reboots] was originally inspired to check out Proxxon tools from one of Hack a Day’s rare tool reviews. The Proxxon TBM115/220 earned the skull ‘n wrenches seal of approval (and found its way into other Hack a Day-ers labs), but sometimes a few hundred dollars is too much of an investment for something only used occasionally. Considering [reboots]’ scrap aluminum drill press is a better tool than the sloppy consumer rotary tool presses, we’ll call this a success.

Adding a laser sight to your drill press in just a few easy steps

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[Derek] was using his Dremel drill press to prep a bunch of PCBs, and found that it was getting difficult to focus on the spinning drill bit each time to line it up with the solder pads on the boards. He figured that a laser sight would help move the process along, but since no off the shelf solution was available for his press, he built one of his own.

He bought a cheap desk lamp with a flexible metal neck, which he disassembled, saving the flexible metal sheath. He installed a conduit clamp on one end of the neck, and a laser module at the other. [Derek] then mounted the laser arm on the press’ crow’s nest aiming it at the tip of the drill bit.

As you can see in the video below, the ability to easily position the drill bit using the laser helps him make quick work of any PCB.

Continue reading “Adding a laser sight to your drill press in just a few easy steps”

Semi-automatic PCB drill press

Kiss the days of breaking bits while drilling through-hole PCBs goodbye thanks to this semi-automatic drill press (translated). Now it’s not going to line up the bit with the exact location of the hole (that would make it a fully automatic drill press). This works by lining up the board manually, then stepping on a pedal to activate the plunging motion of the drill.

A linear motor is responsible for the smooth, accurate motion along the Z-axis. Many hobby setups use a Dremel drill press, or even rely on prayer-based systems such as doing it free-hand with a rotary tool or by using a piece of acrylic as a guide hole. The hobby drill press tends to have some play in it and free-handing with tiny bits that are as fragile as glass both result in far too many broken drill bits. In the video after the break you can see that the linear motion is perfectly plumb with the table of the device, preventing the movements that cause breakage. The addition of the pedal makes it easy to position the boards because you can use both hands.

Having a tool like this takes all of the frustration out of using through-hole parts.

Continue reading “Semi-automatic PCB drill press”

Drill press for through-hole PCB manufacturing

This drill press was built to drill through-hole printed circuit boards. [Rhys Goodwin] didn’t want to shell out for new equipment, so he dug through his scraps to see what he could accomplish. He already had the power drill, and there was no shortage of wood and fasteners. Once he had a mounting platform for the power tool he grabbed a pair of slides from and old rack-mount server rail. This provides smooth and precise movement, along with a tension sprint to keep the rig elevated above the work surface. Turns out the only thing he didn’t already have was the mini-chuck for gripping the 0.8 mm drill bit.

It seems as if [Rhys] is hacking up a storm lately. This drill press is for use with his Inkjet/Toner PCB process from two weeks ago. We also covered his bulk component salvaging system in Sunday’s Links post.