Year: 2010

Copper-clad Enclosures

December 8, 2010 by 29 Comments

Building a great looking box for your projects can be a challenge. [Ken] boils down his process of building enclosures out of copper clad (PDF) circuit board material into an illustrated guide in case you want to try this for yourself. Why would you want to use PC board? The fiberglass substrate makes for a strong and lightweight material. Also, [Ken] is a ham radio operator and the copper coating acts as an electrical shield for delicate components inside.

As you can see above he uses solder to tack the pieces together. There’s some important considerations that go along with this method. First, he cuts the pieces just a bit oversized and then sands them flat and square before assembly. Next, he uses some 20 gauge wire as a shim between a ninety-degree joint and a right angle jig. This shim compensates for the shrinking that occurs as the solder cools, making sure the joint gets pulled to a right angle. He even solders nuts in place so that screws can be used to attach the case cover to the chassis.

Yesterday we saw toner transfer used to make labels on an ABS case. If you make your enclosure out of copper clad, using toner transfer for panel labels will be a snap!

The Twelve Days Of… Self-replicating

December 8, 2010 by 24 Comments

Okay, it’s more like the 23 days but who’s counting? [Kliment] is giving the gift of self-replication this holiday season by uploading one new printable part a day. If you follow along and print each one you’ll have a Prusa Mendel by Christmas (this started on 12/2 so you’ll need to catch up). The Prusa is a variation on the Mendel that uses bushings wherever possible, reducing the need for bearings down to just two.

So yeah, you need to have access to a 3D printer in order to make the parts for this 3D printer, but that’s how it always works. [Kliment] has gone the distance to make this little exercise enjoyable. The parts that take longer to print are reserved for the weekends, some have been altered to include a holiday theme, and all of them have been optimized to fit on a Makerbot build platform.

[Thanks Christopher]

Vintage Car Audio Gets MP3 Input

December 8, 2010 by 20 Comments

[Nali] is fixing up a 1966 Rambler Ambassador and decided to give the audio a bit of an upgrade. Instead of replacing the head unit he added a connector for audio input. The method he used is simple, inexpensive, and allows the original unit to continue functioning as a radio. He cut the feed wires going to the volume knob and patched in a headphone jack. The jack he used has an internal switch that is meant to switch off a pair of speakers when headphones are plugged in. The jack will allow the original signal from the radio tuner to pass through whenever there isn’t a connector plugged in. It seems like this is easier on older hardware than it is on modern equipment.

This isn’t where his entertainment enhancements stop. [Nali’s] working on a 7″ in-dash Linux machine so keep your eye on his thread to see what he comes up with.

[Thanks Joel383]

Christmas Tree Low-water Monitor

December 8, 2010 by 24 Comments

The end of the year is rapidly approaching and there’s a good chance you have a slowly dying tree in your living room. Help it hold on a little longer by using [Eric Ayars’] Christmas Tree water monitor. He’s built a sensor out of a piece of strip board. Three bus strips on the board allow for a variety of alerts. When all three are submerged everything is ok. When the two longer traces are still under water but the third is not an LED will blink to let you know it’s time. If you don’t pay attention and there’s no water left, a piezo buzzer makes noise until you add water (or the coin cell runs out of juice).

This project centers around an ATtiny85 that [Eric] programmed using an Arduino, one of the methods we covered in our AVR Programming Tutorial. But if this simple circuit isn’t high-tech enough for you, we saw a similar method last year that will send an alert to your iPhone.

How To Work With EL Wire

December 7, 2010 by 17 Comments

As you can see, [Phillip Torrone] has a nice start on his Tron costume for the movie premiere. Electroluminescent wire is what makes these costumes glow and if you’ve never worked with the stuff before you’re in for a treat. Adafruit posted a tutorial explaining how to work with EL wire. The process isn’t hard, but they’ve got a few nice tips, like using copper tape as a platform for soldering the corona wires. There is also a discussion of the math involved with properly powering your setup.

In this case, Adafruit is using ready-made power inverter units. If you’ve interested in hacking together your own inverter take a look at the background information from [Jeri Ellsworth].

Nails And Some Blacksmithing

December 7, 2010 by 36 Comments

Here’s a blacksmith turning 4 inch framing nails into buckles. In the clip after the break he starts by heating and bending the nail around a square form. Next the excess gets cut off and both sides of the square frame are ground flat while in a vise. A smaller nail serves as the prong and a flat piece of metal is shaped so that this can be connected to a leather strap. This ends up as part of the support system for a full suit of armor.

We’ve seen a lot of great welding projects over the years, but today’s blacksmithing video leaves us wanting. If you’ve got a favorite project that involved this kind of work tip us off about it and we’ll see if we can get some more hacks for the Smithies out there.

Continue reading “Nails And Some Blacksmithing” →

Radio Controlled Hard Drive Security

December 7, 2010 by 46 Comments

[Samimy] has put together this really neat video tutorial on building a Radio Controlled secure hard drive. How can a hard drive be radio controlled? That’s the first thing we thought too. He has torn apart a remote-controlled car and is using the guts to remotely switch on power to the drive. This means that the drive is only active if you boot the computer after you put the fob in the hidden security system. It looks like it would be fairly effective. We’re curious though, if he is putting the entire drive assembly inside his PC, why rely on batteries for the circuit? Why not pull from the PC power supply? Another neat upgrade might be connecting to an internal USB connection on the motherboard so a reboot isn’t necessary.

Check out the entire video after the break.
Continue reading “Radio Controlled Hard Drive Security” →