[Seandavid010] recently purchased a 2004 Volvo. He really liked the car except for the fact that it was missing some more modern features. He didn’t come stock with any navigation system or Bluetooth capabilities. After adding Bluetooth functionality to the stock stereo himself, he realized he would need a secure location to place his iPhone. This would allow him to control the stereo or use the navigation functions with ease. He ended up building a custom iPhone mount in just a single afternoon.
The key to this project is that the Volvo has an empty pocket on the left side of the stereo. It’s an oddly shaped vertical pocket that doesn’t seem to have any real use. [Seandavid010] decided this would be the perfect place to mount his phone. The only problem was that he didn’t want to make any permanent changes to his car. This meant no drilling into the dash and no gluing.
[Seandavid010] started by lining the pocket with blue masking tape. He then added an additional lining of plastic wrap. All of this was to protect the dashboard from what was to come next. He filled about half of the pocket with epoxy putty. We’ve seen this stuff used before in a similar project. He left a small opening in the middle with a thick washer mounted perpendicular to the ground. The washer would provide a place for an off-the-shelf iPhone holder to mount onto. [Seandavid010] also placed a flat, wooden paint stirrer underneath the putty. This created a pocket that would allow him to route cables and adapters underneath this new mount.
After letting the epoxy putty cure for an hour, he removed the block from the pocket. The stick was then removed, and any gaps were filled in with putty. The whole block was trimmed and smooth down for a more streamlined look. Finally, it was painted over with some flat black spray paint to match the color of the dashboard. An aftermarket iPhone holder allows [Seandavid010] to mount his cell phone to this new bracket. The cell phone holder allows him to rotate the phone into portrait or landscape mode, and even is adjustable to accommodate different sized phones.
One of the first problems every new hacker/maker must solve is this: What’s the best way to attach part “A” to part “B”. We all have our go-to solutions. Hot glue, duck tape ( “duct tape” if you prefer) or maybe even zip ties. Super glue, epoxy, and if we’re feeling extra MacGyver-ish then it’s time for some bubble gum. For some Hackaday readers, this stuff will seem like old hat, but for a beginner it can be a source of much frustration. Even well versed hackers might pick up a few handy tips and tricks presented in this video after the break.
In part one of this series, [Ben Krasnow] shows us the proper use of just a few of the tools and techniques he uses in his shop. [Ben] starts out with a zip-tie tool which he loves in part because of a tension setting that ensures it’s tight but not overly. He moves on to advice for adhesive-vs-material and some tips on using threaded fasteners in several different circumstances. He also included a list of the parts and tools he uses so you don’t have to go hunting them down.
[Ben] is no stranger to us here at Hackaday. He does some epic science video. You can subscribe to his channel or follow his blog if you enjoy what you see.
Continue reading “How to Zip, Stick, and Screw Stuff Together”
We see more and more projects that use custom molds and casting materials. The latest is this custom seven segment display which [Ray74] put together. The idea of making your own LED displays couldn’t be much easier than this — everything but the LEDs and wire is available at the craft store.
He started by making models of each segment out of pink erasers. The lower left image of the vignette above shows the eraser segments super glued to some poster board. The decimal is a pencil eraser, with a fence of wood to contain the molding material. Amazing Mold Putty was mixed and pressed into place resulting in the mold shown in the upper right.
From there, [Ray] cast the clear epoxy three times. Once dried the clear pieces were sanded, which will shape them up physically but also serves to diffuse the light. They were then placed inside of another mold form and an epoxy pour — this time doped with black enamel paint — finishes the 7-segment module. The final step is to glue the LEDs on the back side and wire them up.
This definitely trumps the build which Hackaday Alum [Kevin Dady] pulled off using hot glue sticks as light pipes.
And here we’ve been complaining about Flat Pack No-Lead chips when this guy is prototyping with Ball Grid Array in a Wafer-Level Chip Scale Package (WLCSP). Haven’t heard that acronym before? Neither had we. It means you get the silicon wafer without a plastic housing in order to save space in your design. Want to use that on a breadboard. You’re crazy!
Eh, that’s just a knee jerk reaction. The wafer-level isn’t that unorthodox as far as manufacturing goes. It’s something like chip on board electronics which have that black blob of epoxy sealing them after the connections are made. This image shows those connections which use magnet wire on a DIP breakout board. [Jason] used epoxy to glue the wafer down before grabbing his iron. It took 90 minutes to solder the nine connections, but his second attempt cut that process down to just 20. After a round of testing he used more epoxy to completely encase the chip and wires.
It works for parts with low pin-counts. But add one row/column and you’re talking about making sixteen perfect connections instead of just nine.
This glowing LED is proof that the experiments [Nvermeer] is doing with conductive ink are working. We’re filing this one as a chemistry hack because you need to hit the lab ahead of time in order to get the conductivity necessary for success. He reports that this technique uses a copper powder suspended in an epoxy intended for spray painting. Before mixing the two he etched the powder in ammonium persulfate, then washed it in deionized water which made it a much better conductor.
We gather that the ink was applied with the brush seen in the photo. But since this uses that spray paint friendly solution to host the copper powder we wonder about stenciling with something like masking tape in order to spray the circuit paths onto the substrate.
There’s not too much info up yet, but [Nvermeer] does link to one of our other favorite conductive ink projects.
[Jykazu] wanted to use an external lens with his Kodak Zi8 but he didn’t want to alter the camera or glue something onto it. His solution was to build a bracket out of epoxy dough. He first covers the camera in scotch tape to protect the finish, then he kneads the dough to mix the two parts together, using it to form the bracket that you can see above. After curing, the bracket barely sticks to the smooth tape and can be gently removed. A lens cap with a hole drilled in it is glued to this bracket and works like a charm for connecting the lens. Check out his manufacturing method in the videos after the break.
This is a great method for many applications. Last year we saw a product called Sugru which seems to be made for this type of thing but [Jykazu’s] epoxy method is just as impressive.
Continue reading “Building removable epoxy mounting brackets”