Stop Buying Expensive Circular Saw Blades, Use Paper Instead

August 28, 2016 by Gerrit Coetzee 54 Comments

[John Heisz] was contemplating the secrets of the universe when an errant thought led him to wonder, could I use a sheet of paper as the blade in my table saw?

He takes a sheet of regular printer paper, draws a circle on it the same diameter as his regular blades, and cuts it out. He then bolts it into place on the spindle, slots in the table saw insert for really really thin kerf blades, and fires it up.

The blade is surprisingly dangerous. One would maybe expect a paper blade to be minimally damaging to a finger at best, but it quickly shows itself to be capable of tearing through paper and cutting through wood at a reasonable clip. Since the paper is minimally conductive, a SawStop couldn’t save someone from a lack of caution.

The blade finally meets its match half way through a half-inch thick piece of wood scrap. Wood and paper dust explode outward as the experiment ends. Video after the break.

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Concrete Table Just The Way You Like It

May 11, 2016 by Gerrit Coetzee 14 Comments

You need a coffee table, you need a dinner table. Do you really need two tables? [Shua] thinks the answer is “no”. That’s why he built this swinging countersink table out of concrete and a aluminum.

He started by making a simple half-scale prototype. Then a larger one. Through these explorations he learned how the table would be made, what kind of weight it needed, and how the mechanics needed to be constructed for the most stable table top.

Next he designed the final table in Autodesk Revit. This is software traditionally used for architecture. Since the table was to be made from concrete Revit’s useful set of concrete tools were useful for this project.

Most of the construction process was pretty standard. However, the use of CNC’d pink insulation as a mold for the concrete was interesting. The foam is closed cell, so it worked fine and gave a nice finish. The assembly was finished with a glass top and a carpeted base that contained a surge suppressor and two outlets. The table can be seen swinging between two positions in a video after the break.

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A Better Expanding Table

December 27, 2015 by Brian Benchoff 15 Comments

About a year ago, [Scott] completed what is probably one of the finest builds ever shown on a YouTube channel. It was an expanding wooden table, a build inspired by a fantastically expensive expanding table that was itself inspired by a creation by a mad woodworker in the early 1800s. Although [Scott]’s table is a very well-engineered build, there were a few things he wasn’t happy with. Over the past few months he’s been refining the design and has come up with the final iteration – and plans – for a wooden mechanical expanding table.

Late last year, [Scott] had about 450 hours of design and build time in his table, and by the time he got to the proof of concept stage, he simply ran out of steam. Another year brings renewed enthusiasm, and over the past month or so he’s been working on much-needed improvements to his expanding table that included a skirt for the side of the table, and improvements to the mechanics.

The expanding table is rather thick with three layers of tabletop stacked on top of each other, and those exposed mechanical linkages should be hidden. This means a skirt, and that requires a huge wooden ring. [Scott] built a ring 5 1/2″ deep, about an inch and a half thick, and has the same diameter of the table itself. This means cutting up a lot of plywood, and stacking, gluing, sanding, and routing the entire thing into a perfectly round shape.

The other upgrades were really about the fit and finish of the internal mechanics of the table. Screws were changed out, additional brackets were crafted, and the mounts for the internal ‘star’ was upgraded.

After all that work, is the table done? No, not quite; the skirt could use a veneer, proper legs need to be built, and the entire thing could use a finish. Still, this is the most complete homebuilt expanding table ever conceived, and [Scott] has the plans for his table available for anyone who would want to replicate his work.

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Router Jig Makes Quick Work Of Flattening Irregular Shaped Wood

May 6, 2015 by Rich Bremer 27 Comments

[Nick Offerman] is a pretty serious wood worker. He likes to make crazy stuff including organic looking tables out of huge chunks of wood. Clearly, the wood doesn’t come out of the ground shaped like the above photo, it has to be intensely worked. [Nick] doesn’t have a huge saw or belt sander that can handle these massive blocks of wood so he built something that could. It’s a jig that allows him to use a standard wood router to shave each side down flat.

The process starts by taking a piece of tree trunk and roughing it into shape with a chainsaw. Once it is flat enough to not roll around, it’s put into a large jig with 4 posts. Horizontal beams are clamped to the posts and support a wooden tray which a wood router can slide back and forth in. The router’s cutting bit sticks out the bottom of the tray and slowly nibbles the surface flat. Once one side is flat, the block is rotated and the flat side is used as a reference to make all the other sides square to the first. After flattening, sanding and finishing the block results in a pretty sweet piece of functional artwork.

An Expanding Wooden Table

December 7, 2014 by Brian Benchoff 28 Comments

A few years ago, the world of fine woodworking was presented with the Fletcher Capstan table. It’s a round table, able to expand its diameter merely by rotating the top. A gloriously engineered bit of mechanics move the leaves of the tables out while simultaneously raising the inner part of the table. It’s a seriously cool table, very expensive, and something that will probably be found in museums 100 years from now.

[Scott Rumschlag] thought his woodworking skills were up to the task of creating one of these expanding tables and managed to build one in his workshop. Like the Fletcher Capstan table, it’s a table that increases its diameter simply by rotating the table top. Unlike the commercial offering, this one doesn’t cost as much as a car, and you can actually see the internal mechanism inside this table.

The top of [Scott]’s table is made of three pieces. The quarter-circle pieces are the only thing showing when the table is in its minimum position, and are arranged on the top of the ‘leaf stack’. When the table expands, four additional leaves move up from beneath with the help of a linear bearing made of wood and a roller that slides along the base of this mechanical contraption.

The center of the table – the star – is a bit more difficult to design. While the leaves move up the stack of table tops with the help of a ramp, this is an impractical solution for something so close to the center of the table. Instead of a ramp, [Scott] is using a lifting lever and metal hinge that brings the star of the table up to the right level. Even though it’s a crazy amount of woodworking and fine tuning to get everything right, it’s not too terribly difficult to get your head around.

Videos, including one of the assembly of the table, below.

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End Table Kegerator Hides The Tap When You’re Not Looking

September 8, 2014 by Rick Osgood 31 Comments

What’s better than an ordinary end table? How about an end table that can serve you beer? [Sam] had this exact idea and used his skills to make it a reality. The first step of the build was to acquire an end table that was big enough to hold all of the components for a functional kegerator. This proved to be a bit tricky, but [Sam] got lucky and scored a proper end table from a garage sale for only $5.00.

Next, [Sam] used bathroom sealant to seal up all of the cracks in the end table. This step is important to keep the inside cold. Good insulation will keep the beer colder, while using less electricity. Next, a hole was cut into the top of the table for the draft tower.

The draft tower is mounted to a couple of drawer slides. This allows the tower to raise up and down, keeping it out of sight when you don’t want it. The tower raises and lowers using a simple pulley system. A thin, high strength rope is attached to the tower. The other end is attached to a spool and a small motor. The motor can wind or unwind the spool in order to raise and lower the tower.

The table houses an Arduino, which controls the motor via a homemade H bridge. The Arduino is hooked up to a temperature sensor and a small LCD screen. This way, the users can see how cold their beer will be before they drink it.

To actually keep the beer cold, [Sam] ripped apart a mini fridge. He moved the compressor and condenser coils to the new table. He had to bend the coils to fit, taking care not to kink them. Finally he threw in the small keg, co2 tank and regulator. The final product is a livingroom gem that provides beer on demand.

Demo video (which is going the wrong way) can be found after the break.

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Hackaday Links: August 3, 2014

August 3, 2014 by Brian Benchoff 70 Comments

A ton of people sent in this video of crazy Russians who have taken a microwave, removed the magnetron, taped it to a broom, and turned it on. Don’t try this at home. Or near us.

You know the Google Cardboard kit that’s a real VR headset made of cardboard (and a smart phone)? Google may have gotten their inspiration from Oculus, because every Oculus Rift DK2 ships with a Samsung Galaxy Note 3 inside.

Ever design a PCB and be disappointed by the quality of the silkscreen? [Paul Allen] has been defining the edges of his PCB labels with the copper layer, and the examples are dramatic. Etching copper is what you actually pay for when you fab a board, so it should come as no surprise that the quality is a little higher.

Dunk tanks are fun, but how about competitive dunk tanks? [Chad] built a dunk tank (really more of a ‘dunk shower’) out of a 2×4 tripod, a garbage can, and a few parts from a the toilet aisle of Home Depot’s plumbing department. Then he built a second. Set up both dunk showers across from each other, give two people a few balls, and see who gets soaked last. Looks fun.

Want a MAME cabinet, but don’t want it taking up room in your house? Build a MAME coffee table! Here’s the reddit thread. Maybe we’re old-fashioned, but we’d rather have a giant NES controller coffee table.

Last week we saw a 16-bobbin rope braiding machine, but odd braiding machines like this aren’t limited to fibers. Here’s a wire twisting machine for making RS422 cables. It only produces a single twisted pair, but that’s really all you need to create a cable. Somebody get some paracord and make some Cat5.