Never underestimate the importance of fixturing when you’re machining parts. No matter what the material, firmly locking it down is the key to good results, and may be the difference between a pleasant afternoon in the shop and a day in the Emergency Room. Flying parts and shattered tooling are no joke, but a lot of times quality commercial solutions are expensive and, well, commercial. So this scratch-built drill press vise is something the thrifty metalworker may want to consider.
To be sure, [Ollari’s] vise, made as it is almost completely from scrap angle iron, is no substitute for a vise made from precision ground castings. But it’s clear that he has taken great care to keep everything as square and true as possible, and we give him full marks for maximizing his materials. And his tools — nothing more complicated than a MIG welder is used, and most of the fabrication is accomplished with simple hand tools. We like the way he built up sturdy profiles by welding strap stock across the legs of the angle iron used for the jaws, to give them a strong triangular cross-section to handle the clamping force. And using the knurled end of an old socket wrench as the handle was inspired; we’ll certainly be filing that idea away for a rainy day in the shop. Although we might use Acme rather than plain threaded rod.
We always enjoy seeing someone fabricate their own tools, and this one reminds us a bit of the full-size bench vise built up from layers of welded steel we featured a while back. It even looks a little like this 3D-printed vise, too.
Continue reading “A Scratch-Built Drill Press Vise From Scrap”
Deep in the mojave, the largest aircraft ever made will soon be making test flights. This is the Stratolaunch, and it’s measured the largest to ever fly based on wingspan. The Stratolaunch was constructed out of two 747s, and is designed for a single purpose: as a mobile launch platform for orbital rockets.
There are a couple of ways to measure the size of an aircraft. The AN-225 Mriya has the highest payload capacity, but only one of those was ever built (though that might change soon). The Spruce Goose was formerly the largest aircraft by wingspan, but it only flew once, and only in ground effect. The Stratolaunch is in another category entirely. This is an aircraft that contains some of the largest composite structures on the planet. Not only can you park a school bus between the fuselages of the Stratolaunch, you can strap that school bus to the plane and carry it up to 30,000 feet.
But why build this astonishing aircraft? The reasons go back more than a decade, and the end result is a spaceplane.
Continue reading “The Largest Aircraft Ever Built Will Soon Launch Rockets To Space”
Electric bikes are getting a lot of attention lately. Pretty much anyone can buy a kit online and get a perfectly street legal ride with plenty of range. But if you don’t want to take the kit route, and you’d rather take a tack that will get you noticed more around these parts, take some notes from [Jule553648]’s recent build that definitely isn’t using any parts from a kit.
The motor from the build is an electric power steering pump from a junkyard car. This gets mounted on a one-off rear bike rack and drives the rear tire with help from some gears from a pocket bike gearbox from eBay. A lot of the parts in this build were designed and built using CAD and a machine shop, and the parts for the battery and the power controller were sourced via China to save on cost.
The whole build has a homemade vibe that we find irresistible. The bike can go 35 km/h on level ground without breaking a sweat and has about 40 km of range which is nothing to scoff at. It might even be street legal depending on the wattage of the motor and whether or not you live in Europe (where throttles are generally not allowed on electric bikes). If you’re lacking a machine shop, though, we featured a very well-built kit ebike a while back that you could use as a model to get your feet wet.
Continue reading “Power Steering Pump Repurposed For Great Speed”
Many low-cost wireless temperature and humidity sensors use a 433 MHz transmitter to send data back to their base stations. This is a great choice for the manufacturer of said devices because it’s simple and the radios are cheap, but it does limit what we as the consumer can do with it a bit. Generally speaking, you won’t be reading data from these sensors on your computer unless you’ve got an SDR device and some experience with GNU Radio and reading the Nexus protocol.
But [Aquaticus] has developed a very comprehensive piece of software that should make integrating these type of sensors into your home automation system much easier, as long as you’ve got a spare Raspberry Pi lying around. Called nexus433, it uses a cheap 433 MHz receiver connected to the Pi’s GPIO pins to receive data from environmental sensors using the popular Nexus communication protocol. A few known compatible sensors are listed in the project documentation, one of which can be had for as little as $5 USD shipped.
In addition to publishing the temperature, humidity, and battery level values from the sensors to MQTT, it even tracks connection quality for each individual sensor and when they go on and offline. To be sure, this is no simple hack. In nexus433, [Aquaticus] has created a mature Linux service with enough flexibility that you shouldn’t have any problems working it into your automation setup, whether it’s Home Assistant or something you’ve put together yourself.
We’ve seen a number of home automation hacks using these ubiquitous 433 MHz radios, from controlling them with an ESP8266 to hacking a popular TP-LINK router into a low-cost home automation hub.