DIY Powder Coating

If you don’t yet have a toaster oven you can’t use with food, here’s yet another reason: DIY powder coating. Powder coating is much harder and more durable than paint – a property imbued to it by the fact that it’s baked on to a part. [Thomas] had a go at powder coating some skateboard trucks, and with the right tools, found the process downright easy.

[Thomas] only needed a few things to powder coat his parts, the first and most important being a powder coat gun. A few years ago, Craftsman produced a powder coat gun that’s still available on Amazon and eBay for about $50. Powders are plentiful and cheap in small quantities. The only other tools needed were an N95 or better respirator, some high temperature tape for masking off the part and a toaster oven. If you want to coat big parts, there are DIY oven options for that.

After the part was sandblasted down to bare metal, [Thomas] masked off all the holes and threads of the part with polyimide tape. Any tape that’s capable of withstanding high temperatures will do, and most of us have a roll of Kapton sitting next to a 3D printer, anyway.

The part is coated with powder via an electrostatic charge, and this means attaching a ground lead from the gun to the part. After that, it’s just filling the gun with powder, putting it in the oven set at 450°F, and letting the powder liquefy.

In the video below, you can see [Thomas] sandblasting, powdering, and baking a set of aluminum skateboard trucks using his method. Compared to other methods of finishing metal parts – anodizing or plating, for instance, powder coating is remarkably easy and something anyone can do in a garage.

Thanks [Tyler] for sending this one in.

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[Will] had a few reasons for turning a toaster oven into a reflow oven – he needed a project for an ECE lab, the lab’s current reflow oven was terrible, and the man is trying to keep [Will] down by not allowing toaster ovens in dorm rooms. What was born out of necessity actually turned into a great project – a reflow oven with touchscreen controls.

The toaster oven used for this build is a model [Will] picked up at Sears. It’s actually pretty unique, advertised as a ‘digital toaster’. This isn’t marketing speak – there’s actually a thermistor in there, and the stock toaster is closed loop. After disassembling the toaster and getting rid of the guts, [Will] whipped up a PCB for a Teensy 3.1 and the Adafruit capacative touch shield.

With the Teensy and touch screen, [Will] came up with an interface that looks ten times better than anything you would find on a Chinese auction site. It’s a great build, and since it’s kept in the electronics lab, will certainly see a lot of use.

Toaster Oven Reflow Controllers

With a lot of people who are suddenly too cool for through hole and of course the a few generations of components that are only available in SMD packages, it’s no surprise the humble toaster oven has become one of the mainstays of electronic prototyping. You’re gonna need a controller to ramp up those temperatures, so here are two that do the job quite nicely.

[Nathan]’s Zallus Oven Controller is a bit different than other reflow controllers we’ve seen on Kickstarter. He’s offering three versions, two with different sized touch screen displays, and one that is controlled with a PC and push buttons. The display for these is beautiful, and of course you can program your own temperature profiles.

If Kickstarter isn’t your thing, [Dirk] created his own reflow controller. Like the Zallus, this has a graphical display, but its homebrew lineage means it should be simpler to maintain. It uses a K-type thermocouple, and unlike every other reflow controller we’ve ever seen, [Dirk] is actually checking the accuracy of his temperature probe.

No, reflow oven controllers aren’t new, and they aren’t very exciting. They are, however, tools to build much cooler stuff, and a great addition to any lab.

An Amazing DIY Single Board ARM Computer with BGA

DIY Single Board Computer ARM

Typically, you buy a single board Linux computer. [Henrik] had a better idea, build his own ARM based single board computer! How did he do it? By not being scared of ball grid array (BGA) ARM processors.

Everyone loves the Raspberry Pi and Beagle Board, but what is the fun in buying something that you can build? We have a hunch that most of our readers stay clear of BGA chips, and for good reason. Arguably, one of the most important aspects of [Henrik’s] post is that you can easily solder BGAs with cheaply available tools. OSH Park provides the inexpensive high-quality PCBs, OSH Stencils provides the inexpensive stencils, and any toaster oven allows you to solder even the most difficult of components. Not only does he go over the PCB build, he also discusses the bootloader, u-boot, and how to get Linux running.

Everything worked out very well for [Henrik]. It’s a good thing too, cause we sure wouldn’t want to debug a PCB as complicated as this one. What projects have you built that use a BGA? Let us know how it went!

Hackaday Links: January 12, 2014


[Kyle] teaches photography and after being dismayed at the shuttering of film and darkroom programs at schools the world over decided to create a resource for film photography. There’s a lot of cool stuff on here like mixing up a batch of Rodinal developer with Tylenol, lye, and sodium sulphite, and assessing flea market film cameras. There are more tutorials coming that will include setting up a dark room, developing prints, and playing around with large format cameras.

[hifatpeople] built a binary calculator out of LEGO® bricks or toys. It started off as a series of logic gates built out of LEGO® bricks or toys in the LEGO® Digital Designer. These logic gates were combined into half adders, the half adders combined into full adders, and the full adders combined into a huge plastic calculator. Unfortunately, buying the LEGO® bricks or toys necessary to turn this digital design into a physical model would cost about $1000 using the LEGO® Pick-A-Brick service. Does anyone have a ton of LEGO® Technic® bricks or toys sitting around? We’d love to see this built.

Think you need a PID controller and fancy electronics to do reflow soldering in a toaster oven? Not so, it seems. [Sivan] is just using a meter with a thermocouple, a kitchen timer, and a little bit of patience to reflow solder very easily.

The folks at DreamSourceLabs realized a lot of electronic test equipment – from oscilloscopes and logic analyzers to protocol and RF analyzers were all included a sampling circuit. They designed the DSLogic that puts a sampler and USB plug on one board, with a whole bunch of different tools connected to a pin header. It’s a pretty cool idea for a modular approach to test equipment.

Adafruit just released an iDevice game. It’s a resistor color code game and much more educational than Candy Crush. With a $0.99 coupon for the Adafruit store, it’s effectively free if you’re buying anything at Adafruit anytime soon. Check out the video and the awesome adorable component “muppets”.

A Pair of Toaster Reflow Oven Builds


For some reason or another, the Hackaday tip line sometimes sees a short burst of submissions for the same project. The latest one of these was for toaster oven reflow stations. They’re both great builds and different approaches to making a useful tool out of home appliances.

First up is [Richard]’s build. he ended up with a fairly high-end build using a Rocket Scream Reflow Oven Controller Arduino shield. This shield accepts a normal K-type thermocouple and controls an external solid state relay with the Arduino’s PID library. [Richard]’s build has a few neat additions – a properly dremeled enclosure, computer fan, and a welding blanket for insulation. Now that we think about it, it’s odd we’ve rarely seen any sort of insulation in these reflow oven builds.

Next up is [Ray]’s version of a Black & Decker reflow oven. While not as fancy as [Richard]’s build, this one does have a few features that make it very interesting. Instead of messing around with thermocouples, [Ray] simply took a digital kitchen thermometer – a neat tool that already a thermistor in a compact metal probe – and read the analog value with an Arduino. To control the power, [Ray] is using a cheap 433 MHz radio transmitter to control a few remotely operated power sockets. It’s a very clever and inexpensive replacement for a SSR, especially since [Ray] had these power sockets just lying around.

So there you go. The same tool, built two different ways. A great demonstration of how you can not only build anything, but you can build anything any way you want.

Reflow oven courtesy of hurricane Sandy


The Makerbar, Hoboken’s Hackerspace, was in desperate need of a reflow oven. Hurricane Sandy did a number on a whole bunch of household appliances, so when [Kush] saw a neighbor throw out a broken toaster oven, the Makerbar crew sprung into action.

The storm waters shorted the electronics board, fried the existing controls, and basically turned the oven into a metal shell with heating elements. It was the perfect platform for a toaster oven – every part that was going to be thrown out was already destroyed.

[Zach] over at the Makerbar ordered the Sparkfun reflow toaster conversion kit along with a few arcade buttons and set to work. After plugging the heating elements into the mains power to make sure they still worked, [Zach] attached these elements to the relay on board the controller. Three arcade buttons were wired up to the controller, and a whole bunch of code was written.

With the included thermocouple, [Zach], [Kush], and the rest of the Makerbar gang now have a very accurate and reliable reflow oven. There’s also settings for Sculpey clay and shrinky dinks, just in case anyone at Makerbar is feeling a bit creative.