Reviving A $25 Generator

September 22, 2017 by Adam Fabio 35 Comments

[Jennies Garage] found a used and abused inverter based generator in the clearance section of his local home improvement store. The generator had been returned on a warranty claim and was deemed uneconomical to fix. Originally $799, [Jennies Garage] picked it up for just $25. He documented his quest to get the device running with a trio of videos.

The generator had spark, but didn’t want to fire. The only obvious problem was the fact that the machine had been overfilled with oil. There was little or no compression, but that is not uncommon with modern small engines – many of them have a compression release mechanism which makes them easier to start.

With all the obvious problems eliminated, the only thing left to do was tear into the engine and figure out what was wrong. Sure enough, it was a compression issue. The overfull oil condition had forced engine oil up around the piston rings, causing them to stick, and snapping one of the rings. The cylinder bore was still in good shape though, so all the engine needed was a new set of rings.

That’s when the problems started. At first, the manufacturer couldn’t find the rings in their computer system. Then they found them but the rings would take two weeks to ship. [Jennies Garage] isn’t the patient type though. He looked up the piston manufacturer in China. They would be happy to ship him complete pistons – but the minimum order quantity was 5000. Then he started cross-referencing pistons from other engines and found a close match from a 1960’s era 90cc motorcycle. Ironically, it’s easier to obtain piston rings for an old motorcycle than it is to find them for a late model generator.

The Honda rings weren’t perfect – the two compression rings needed to be ground down about 1/2 a millimeter. The oil ring was a bit too thick, but thankfully the original oil ring was still in good shape.

Once the frankenpiston was assembled, it was time to put the repair to the test. [Jennies Garage] reassembled the generator, guessing at the torque specs he didn’t have. The surgery was a complete success. The generator ran perfectly, and lit up the night at the [Jennies Garage] cabin.

If you’re low on gas, no problem. Did you know you can run a generator on soda? Want to keep an eye on your remote generator? Check out this generator monitor project.

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Arduino And Pi Breathe New Life Into Jukebox

September 22, 2017 by Al Williams 6 Comments

What do you do when someone gives you a Wurlitzer 3100 jukebox from 1969, but keeps all the records? If you are like [Tijuana Rick], you grab an Arduino and a Rasberry Pi and turn it into a really awesome digital music player.

We’ll grant you, making a music player out of a Raspberry Pi isn’t all that cutting edge, but restoration and integration work is really impressive. The machine had many broken switches that had been hastily repaired, so [Rick] had to learn to create silicone molds and cast resin to create replacements. You can see and hear the end result in the video below.

[Rick] was frustrated with jukebox software he could find, until he found some Python code from [Thomas Sprinkmeier]. [Rick] used that code as a base and customized it for his needs.

There’s not much “how to” detail about the castings for the switches, but there are lots of photos and the results were great. We wondered if he considered putting fake 45s in the machine so it at least looked like it was playing vinyl.

Of course, you don’t need an old piece of hardware to make a jukebox. Or, you can compromise and build out a replica.

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FPGA Clocks For Software Developers (or Anyone)

September 21, 2017 by Al Williams 18 Comments

It used to be that designing hardware required schematics and designing software required code. Sure, a lot of people could jump back and forth, but it was clearly a different discipline. Today, a lot of substantial digital design occurs using a hardware description language (HDL) like Verilog or VHDL. These look like software, but as we’ve pointed out many times, it isn’t really the same. [Zipcpu] has a really clear blog post that explains how it is different and why.

[Zipcpu] notes something we’ve seen all too often on the web. Some neophytes will write sequential code using Verilog or VHDL as if it was a conventional programming language. Code like that may even simulate. However, the resulting hardware will — at best — be very inefficient and at worst will not even work.

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The Longest Tech Support Call: Apollo 14 Computer Hack

September 21, 2017 by Al Williams 12 Comments

Deep-voiced and aptly named [Scott Manley] posted a video about the computer hack that saved Apollo 14. Unlike some articles about the incident, [Scott] gets into the technical details in an entertaining way. If you don’t remember, Apollo 14 had an issue where the abort command button would occasionally signal when it shouldn’t.

The common story is that a NASA engineer found a way to reprogram the Apollo guidance computer. However, [Scott] points out that the rope memory in the computer wasn’t reprogrammable and there was no remote way to send commands to the computer anyway.

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Spray Paint Goes DIY Virtual With A Vive Tracker

September 21, 2017 by Donald Papp 11 Comments

Here is a virtual spray painting project with a new and DIY twist to it. [Adam Amaral]’s project is an experiment in using the Vive Tracker, which was released earlier this year. [Adam] demonstrates how to interface some simple hardware and 3D printed parts to the Tracker’s GPIO pins, using it as a custom peripheral that is fully tracked and interactive in the Vive’s VR environment. He details not only the custom spray can controller, but also how to handle the device on the software side in the Unreal engine. The 3D printed “spray can controller” even rattles when shaken!

There’s one more trick. Since the Vive Tracker is wireless and completely self-contained, the completed rattlecan operates independently from the VR headset. This means it’s possible to ditch the goggles and hook up a projector, then use the 3D printed spray can to paint a nearby wall with virtual paint; you can see that part in action in the video embedded below.

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Another Day, Another Air Gap Breached

September 21, 2017 by Dan Maloney 48 Comments

What high-tech, ultra-secure data center would be complete without dozens of video cameras directed both inward and outward? After all, the best informatic security means nothing without physical security. But those eyes in the sky can actually serve as a vector for attack, if this air-gap bridging exploit using networked security cameras is any indication.

It seems like the Cyber Security Lab at Ben-Gurion University is the place where air gaps go to die. They’ve knocked off an impressive array of air gap bridging hacks, like modulating power supply fans and hard drive activity indicators. The current work centers on the IR LED arrays commonly seen encircling the lenses of security cameras for night vision illumination. When a networked camera is compromised with their “aIR-Jumper” malware package, data can be exfiltrated from an otherwise secure facility. Using the camera’s API, aIR-Jumper modulates the IR array for low bit-rate data transfer. The receiver can be as simple as a smartphone, which can see the IR light that remains invisible to the naked eye. A compromised camera can even be used to infiltrate data into an air-gapped network, using cameras to watch for modulated signals. They also demonstrated how arrays of cameras can be federated to provide higher data rates and multiple covert channels with ranges of up to several kilometers.

True, the exploit requires physical access to the cameras to install the malware, but given the abysmal state of web camera security, a little social engineering may be the only thing standing between a secure system and a compromised one.

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Hackaday Prize Entry: Post Stroke Spasticity Rehab Helper

September 21, 2017 by Anool Mahidharia 5 Comments

A stroke is caused when poor blood flow to the brain causes cell damage, causing that part of the brain to stop functioning. Common causes are either blood vessel blockage or internal bleeding, and effects depend on the part of the brain that is affected. In most cases, spasticity (muscle contraction), poor motor control and the inability to move and feel are common after effects. Recovery is often a long, slow process and involves re-learning the affected lost skills. This is where physical therapy using assistive technologies becomes important. Rehabilitation must start as early as possible since the first few weeks are critical for good recovery. [Sergei V. Bogdanov] is building a cheap and simple Post-Stroke Spasticity Rehab Helper to address this problem.

He’s using ten hobby micro servos connected to an Arduino Nano, all mounted on a kitchen chopping board, with a few other bits thrown in to round out the build. There’s one pair of servos for each finger. A five bar linkage converts the servo rotations to two-dimensional motion. The end of the linkage has a swiveling metallic disk. Patient fingers are attached to these discs via magnetic metal pads that are attached to the end of the fingers using adhesive plaster tape. Two push buttons cycle through a large number of exercise modes and two potentiometer’s help adjust the speed and smoothness (the number of points calculated for the desired motion). Two 7-segment LED display modules connected to the Arduino provides a visual interface showing program modes, speed, number of cycles and other relevant information. Replicating the project ought to be very straightforward since the device uses off-the-shelf parts which are easy to put together using the detailed build instructions, photos and code posted on [Sergei]’s project page. Check out the videos below to see the rehab helper in action.