Feel Better About Yourself With These Ugly Repairs

A fun thread over at the EEVblog forum starts off with [TerraHertz]’s triangle-peg, square-hole capacitor repair job and goes entertainingly down-hill from there.

Everything from horrifying eBay purchases to work (horror) stories can be found in this thread. But you can learn something too. Did you know the correct way to fix a mercury switch stored in the incorrect orientation is to whack it against a table really hard?

We enjoyed the cigarette box shroud used to fix a graphics card with a defective fan. We’re still not sure about the person who managed to Dremel bits off a graphics card and end up with a working PCI-e card. That one may be a troll.

Regardless, it’s a lot of fun, spanning the hilariously bad and the seriously impressive. We would not be surprised if some of these people met the devil at the crossroads for some soldering skill. Do any of you have an interesting or ugly repair to share? We’d love to see it.

How To Have an Above Average Time With a Cheap Horizontal Bandsaw

[Quinn Dunki] has brought yet another wayward import tool into her garage. This one, all covered in cosmoline and radiating formaldehyde fumes, is a horizontal bandsaw.

Now, many of us have all have some experience with this particular model of horizontal saw. It waits for us at our work’s machine shop, daring us to rely on it during crunch time. It lingers in the corner of our hackerspace’s metalworking area, permanently stuck in the vertical position; at least until someone finally removes that stripped screw. Either that or it’s been cannibalized for its motor, the castings moldering in a corner of the boneyard.

This article follows on the heels of [Quinn]’s other work, a treatise on the calibration of a drill press, and it outlines all the steps one has to take to bring one of these misunderstood tools into consistent and reliable operation. It starts with cultivating a healthy distrust of the factory’s assurances that this device is, “calibrated,” and needs, “no further attention.” It is not, and it does. Guides have to be percussively maintained out of the blade’s way. Screws have to be loosened and adjusted. It takes some effort to get the machine running right and compromises will have to be made.

In the end though, with a high quality blade on, the machine performs quite well. Producing clean and quality cuts in a variety of materials. A welcome addition to the shop.

Likely Everything You Need To Know Before Adopting A Drill Press

Oh sure, the thought of owning a happy whirring drill press of your very own is exciting, but have you really thought about it? It’s a big responsibility to welcome any tool into the home, even seemingly simple ones like a drill press. Lubricants, spindle runout, chuck mounts, tramming, and more [Quinn Dunki], of no small fame, helps us understand what it needs for happy intergration into its new workshop.

[Quin] covers her own drill press adventure from the first moments it was borne into her garage from the back of a truck to its final installation. She chose one of the affordable models from Grizzly, a Washington based company that does minimal cursory quality control on import machinery before passing on the cost to the consumer.

The first step after inspection and unpacking was to remove all the mysterious lubricants and protectants from the mill and replace them with quality alternatives. After the press is set-up she covers some problems that may be experience and their workarounds. For example, the Morse taper on the chuck had a few rough spots resulting in an incomplete fit. The chuck would work itself loose during heavier drilling operations. She works through the discovery and repair of this defect.

Full of useful tips like tramming the drill press and recommended maintenance, this is one of the best guides on this workshop staple that we’ve read.


The Most Traveled Security Screwdriver, A Hacker’s Tale

Nespresso is a variant of disposable single serve coffee pods with an extensive, expensive, and proprietary accessory line. After selling inconvenient bits of his soul for convenience and, admittedly, fairly tasty shots of coffee, [Chriss Lott] was predictably betrayed by his Nespresso Jura coffee machine. 

Rather than simply exchange more local currency for a replacement revenue guarantee for the Nestle conglomerate, he did what any self-respecting hacker would do and tried to fix it himself. Unfortunately he quickly found their cunningly oval shaped security screws to be more trouble than his time was worth. He listed his remaining coffee pods for free on craigslist and decided to toss the machine in the planned obsolescence receptacle which comes standard in any civilized home.

This is where our story would end were it not for the kindness of a fellow hacker. [Dave H] was browsing through craigslist when he spotted the sad tale. However, possessing a different skillset from [Chris], [Dave] had solved the particular oval shaped conundrum with a security screwdriver hand made from an old bolt. He answered his fellow hacker’s vaguely ardent plea and mailed the converted bolt over to [Chris]’s house.

With the proper tool in hand, [Chris] quickly discovered that all that was standing between him and his convenient coffee was a bit of schmoo between the cost cutting membrane switch and its mating pad on the circuit board. With the practically free repair complete, the machine happily vibrated back to life and produced coffee as if its planned obsolescence wasn’t for another few years. We assume a Nestle engineer was thrown into the pit on principle for this loss (they, of course, are evil enough to have a pit).

We’re not sure how the story proliferated through the internet, but we do know that it was inspirational to many convenient caffeine deprived hackers with similar problems. [Chris] found himself the hub in a network of circumnavigating security screw circumventing hackers.

[Dave]’s hacked bolt was the first to go on an adventure resulting in the repair of many machines before the postmen lost it under a cart, standard procedure. A replacement was purchased from an eBay seller for a hefty $40 american dollars and took up the journey where it left off. Others sent in guides on making the tool for those unwilling to wait for one to be shipped. In fact, even the maker of the $40 dollar tool weighed in on the issue. Apparently he was unaware that the consumer and commercial Nespresso machines used the same tools. A hacker himself, he ran a listing of the custom tool at a quarter of the price for the home repairman and another for the commercial appliance at the higher price.

The whole page is an entertaining read, for a certain kind of person, about appliance repair, reverse engineering, and camaraderie. Happily, the hub is still alive. If you find yourself with an oval screw which needs turning, get in touch with [Chris] and a strange community’s kindness will have a nomadic security bit crossing nations your way soon.

Repairing 14 Tektronix TLA5202 Logic Analyzers

[Matthew D’Asaro] was recently entrusted with an entire classroom fleet of fourteen broken Tektronix TLA5202 logic analyzers — a pile of equipment that once was worth hundreds of thousands of dollars. His task: Fixing them. He fixed them all, and on the way documented a number of common failure points in these old but still great devices.

Continue reading “Repairing 14 Tektronix TLA5202 Logic Analyzers”

Refurbishing Six Commodore 64s in Parallel

[Drygol] found himself with six Commodore 64’s in various states of disrepair. Because batch work is often more efficient, he detailed the process of restoring all of them in parallel in this one-, two-, three-part series.

The first step was to whiten the cases. Old cases turn yellow from the degradation of the fire retardant additives in the plastic. The proven method to fix this is with a paste called Retr0bright. [Drygol] used hair bleaching paste which is very similar. The cases came out nicely whitened from their treatment.

Next he repaired the keyboard PCB and whitened the keys as well. Drinking was involved, but it all came out okay. The circuit boards were cleaned and inspected. There were a few corroded spots, broken chips, and bad solder joints to be repaired. A few common mods were also installed.

In the final part of the series two of the C64s have SD cards installed into them. A few interesting fixes were done to repair broken plastics. Lastly the two worst cases were painted. In the end [Drygol] found himself with six perfectly working and attractive C64s. Who know’s what he’ll do with them, but we all know that was not the point.

Parent To The Power Wheels Rescue

If the [realjohnnybravo] is the one from the show, it appears he finally managed to get a girlfriend, marry her, and produce at least one son. As the old schoolyard rhyme goes, first comes love, then comes marriage, then comes filling the whole *!$&# backyard with brightly colored plastic garbage. One of these items, a Power Wheels quad bike,  suffered a blow from planned obsolescence leaving behind a traumatized child. [realjohnnybravo] decided to fix it.

He made frequent mention of how one could go to a store and purchase replacement gears for the toy. Perhaps it’s a German thing. Regardless, he shows experience with internet comments by justifying his adventure in gear manufacturing with, paraphrased, “I’m having fun and learning so back off you pedantic jerks.”

Resin casting is great, and is often overlooked vs 3D printing. He purchased some hardware store RTV silicone and some slow-cure resin. The faster cure resin would get too hot with this much volume and potentially burn.

Materials procured he took apart both gearboxes from the machine. He first made a silicone mold of the broken parts (from the good copies out of the working gearbox) and removed the master. Without a vacuum or pressure casting chamber, the molds came out a little rough and bubbly, but it’s nothing some work with a carpet knife can’t fix. For big gears like this it hardly matters. Next he poured the two part resin into the molds and waited.

After some finishing with regular woodworking tools the parts fit right into the voids in the defective gearbox. His son can once again happily whir around the lawn, until the batteries die anyway.