The iSore would have definitely made some of us the coolest kids on the yard in Jr. High (or at the engineering office) in the 00’s. At first glance we assumed it would be one of those fancy single board computers packaged with a big hard drive masquerading as an iPod. We were surprised to discover that [jimbone] was performing a classic iPod hack.
The ipod’s back is pried off and discarded. A ZIF to SATA adapter connects it to a significantly larger hard drive. The basic battery is replaced with an 8Ah pack. The USB ports are broken out. For the case there are a few options. There’s a 3D printed case, a wooden case, and even one that looks like a Lovecraftian horror.
[jimbone] claims 100 hours of playtime on a single charge. He hasn’t claimed bulking up a bit from carrying it around, but we can make our guesses.
What happens when you break a tap or a bolt in a component whose price tag sits in the tens of thousands. Just drilling it out and throwing in a nut insert stops being acceptable. Is there a way to remove the tap without damaging the master part at all?
Well, that’s where [Tom Grafton] of Jerry’s Broken Drill and Tap comes in. He’s here to remove taps and chew bubblegum, and he’s definitely chewing bubble gum loudly the whole time. His primary work horse is a Metal Disintegration Machine.
A MDM is basically half of a typical wire EDM set-up. In EDM you used an electrode to punch a hole through the material. Then you thread a wire through the hole, thread it through a sometimes startling array of pulleys, and get going.
[Tom] used the MDM with an appropriately sized electrode to precisely disintegrate the middle of the tap out. After that it’s some careful work with a specially machined magnetic chisel. A quick chase of the threads with a tap and it’s back to the customer.
As you can see in the video after the break, the end result is a threaded hole that’s so indistinguishable from the rest he has to mark which one it was; presumably so the customer doesn’t forget why they’re paying him.