Fixing a Broken Postage Scale

[Starhawk] had an old Pitney Bowes G799 postage scale that wasn’t working as it should. After years of faithfully measuring packages and cooking ingredients, the scale stopped working. At first it fell out of calibration. Then the power up sequence stopped working. The scale normally would turn on, light up the entire display, then change to dashes, and finally set itself to 0.0 lbs. In this case, it would get stuck at the dashes and never change to 0.0.

[Starhawk] ended up purchasing another duplicate scale from eBay, only to find that when it arrived it had the exact same power up problem. Using deductive reasoning, he decided that since the scale was broken during shipping the problem would likely be with a mechanical component. He turned out to be correct. The cheap momentary power button was at fault. When pressing the button, the contact would get stuck closed preventing the scale from zeroing out properly. [Starhawk] easily fixed his problem by replacing the switch.

Next [Starhawk] replaced the old scale’s LCD module with one from the new scale, since the old one looked to be on its way out. The scale still had a problem correctly measuring weight. [Starhawk] tried swapping the load cell from the new scale to the old one, but he found that the new load cell had some kind of problem that prevented the scale from zeroing out properly. The solution ended up being to use the newer “analog board” as [Starhawk] calls it.  The end result was the old scale with two newer circuit boards, an older load cell, and a new power switch. Next time it might be easier to just build his own scale.

Repairing and Reviewing a 1976 PONG Clone

Hackaday alum [Todd] has been searching for an old PONG clone for the last two years. This variant is called, “The Name of the Game”. [Todd] has fond memories of playing this game with his sister when they were young. Unfortunately, being the hacker that he is, [Todd] tore the game apart when he was just 14 to build his own Commodore 64 peripherals. He’s been wanting to make it up to his sister ever since, and he finally found a copy of this game to give to his sister last Christmas.

After opening up the box, [Todd] quickly noticed something strange with the power connector. It looked a bit charred and was wiggling inside of the enclosure. This is indicative of a bad solder joint. [Todd] decided he’d better open it up and have a look before applying power to the device.

It was a good thing he did, because the power connector was barely connected at all. A simple soldering job fixed the problem. While the case was still opened, [Todd] did some sleuthing and noticed that someone else had likely made repairs to several other solder joints. He also looked for any possible short circuits, but everything else looked fine. The system ended up working perfectly the first time it was started.

The end of the video shows that even after all this time, simple games like this can still capture our attention and be fun to play for hours at a time. [Todd] is working on part 2 of this series, where he’ll do a much more in-depth review of the system. You can watch part 1 below. Continue reading “Repairing and Reviewing a 1976 PONG Clone”

Repairing Burnt Speakers with a Steady Hand

[Martin] seems to have a knack for locating lightly damaged second-hand audio gear. Over the years he’s collected various types of gear and made various repairs. His most recent project involved fixing two broken tweeter speakers.

He first he needed to test the tweeters. He had to remove them from the speaker cabinet in order to gain easier access to them. The multimeter showed them as an open-circuit, indicating that they had likely been burned. This is an issue he’s seen in the past with this brand of speaker. When too much power is pumped through the speaker, the tiny magnet wire inside over heats and burns out similar to a fuse.

The voice coil itself was bathing in an oily fluid. The idea is to help keep the coil cool so it doesn’t burn out. With that in mind, the thin wire would have likely burned somewhere outside of the cooling fluid. It turned out that it had become damaged just barely outside of the coil. [Martin] used a sharp blade to sever the connection to the coil. He then made a simple repair by soldering the magnet wire back in place using a very thin iron. We’ve seen similar work before with headphone cables.

He repeated this process on the second tweeter and put everything back together. It worked good as new. This may have ultimately been a very simple fix, but considering the amount of money [Martin] saved on these speakers, it was well worth the minimal effort.

Repairing A Router Plagued By Capacitors

[psgarcha]’s modem/router comes straight from his internet provider, is on 24/7, and is built with the cheapest components imaginable. Eventually, this will be a problem and for [psgarcha], this problem manifested itself sooner than expected. Fortunately, there was a soldering iron handy.

The problems began with a boot loop – starting the router up, watching the blinking LEDs, and watching these lights follow the same pattern forever. Initially thinking this would be a problem with the firmware, [psgarcha] did the only thing he could do – take it apart. Inside, he found some bulging capacitors. Unsheathing his iron and replacing the obviously faulty components, [psgarcha] plugged the router in and had everything work. Great. Until those caps failed again a few months later.

There was obviously something wrong with the circuit, or wrong with the environment. Figuring it was hot out anyway, [psgarcha] replaced those caps again and added a fan and a small heatsink to the largest chip on the board. This should solve any overheating problems, but the real testing must be done in summer (or putting the router in a well-insulated enclosure). It’s an easy fix, a good reminder of exactly how often caps fail, and a great example of reducing the electronic cruft building up in landfills.

Fixing Ghost Touch In The OnePlus One

The OnePlus One is the flagship phone killer for 2014, available only by invite, and thus extremely cool. So far it’s a limited production run and there will, of course, be problems with the first few thousand units. When [vantt1] got his One, he noticed a few issues with the touch screen. Some touches wouldn’t be registered, typing was unpredictable, and generally, the touchscreen was unusable. [vantt] had seen this before, though, so with a complete teardown and a quick fix he was able to turn this phone into something great.

[vantt] realized the symptoms of a crappy touchscreen were extremely similar to an iPad mini that had recently had its digitizer replace. From the Foxconn plant, the digitizer in the iPad mini is well insulated from the aluminium enclosure. When the screen and digitizer are replaced, the cable connecting it to the rest of the iPad can come in contact with the case. This leads to the same symptoms – missed touches, and unpredictable typing.

Figuring the same cure will fix the same symptoms, [vantt] tore apart his OnePlus One and carefully taped off the digitizer flex cable. Reassembling the phone, everything worked beautifully, and without any extra screws in the reassembly process. You can’t do better than that.

Go Vintage! Learn to Repair and Restore Mechanical Pocket and Wrist Watches.

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Until recently, watches have been entirely mechanical where each wheel, gear, and mechanism representing a milestone in our understanding of precision manufacturing and timekeeping.

One of the very first watches, created by a locksmith.
One of the very first watches, created by a locksmith.

Today it is nearly impossible to find watchmakers to service or repair vintage mechanical pocket and wristwatches, so we have to do it ourselves. Learn to repair vintage mechanical watches. You can do this and we’ll show you how.

They tick, mechanical watches have a pulse. First created in the 16th century by locksmiths, these early watches could only resolve time down to the hour and for this reason displayed time with only one hour hand.

By the 18th century fusee technology enabled watches to achieve accuracies to within seconds.

Continue reading “Go Vintage! Learn to Repair and Restore Mechanical Pocket and Wrist Watches.”

Fail of the Week: Projector LED Retrofit

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That’s a deal for a project, how hard could it be to fix it up?

If you’re a real hacker we’d wager you’ve fallen for this type of thought process before. [Luft] bought this used Sharp XR-10X-L projector about a year back and planned to retrofit it with an LED bulb. He gathered all the parts and got to work, successfully testing and installing the modifications. But as luck would have it, the project is stuck in some type of boot loop.

This fail is certainly not for lack of preparation. The first post documenting his adventure shows that the hack has been done before, he acquired the service manual for this particular hardware, and he did his homework when ordering the parts. Success requires circumventing some sensors which ensure the case and internals are in place, and making sure the electronic status of the ballast is reported correctly event though it’s not needed for the LED source. Power-on gets as far as illuminating all the indicator lights in green as it should, but is then followed closely by a reboot sequence.

He tried watching the serial port to see if he can get any status info there but no dice. In keeping with the nature of this column, let’s see if we can provide any constructive troubleshooting advice in the comments.


2013-09-05-Hackaday-Fail-tips-tileFail of the Week is a Hackaday column which runs every Wednesday. Help keep the fun rolling by writing about your past failures and sending us a link to the story — or sending in links to fail write ups you find in your Internet travels.