A broken bolt is removed by welding on a hut and then using a wrench to unscrew.

Using A MIG Welder, Acetylene Torch, And Air Hammer To Remove A Broken Bolt

April 16, 2025 by John Elliot V 13 Comments

If your shop comes complete with a MIG welder, an acetylene torch, and an air hammer, then you have more options than most when it comes to removing broken bolts.

In this short video [Jim’s Automotive Machine Shop, Inc] takes us through the process of removing a broken manifold bolt: use a MIG welder to attach a washer, then attach a suitably sized nut and weld that onto the washer, heat the assembly with the acetylene torch, loosen up any corrosion on the threads by tapping with a hammer, then simply unscrew with your wrench! Everything is easy when you know how!

Of course if your shop doesn’t come complete with a MIG welder and acetylene torch you will have to get by with the old Easy Out screw extractor like the rest of us. And if you are faced with a nasty bolt situation keep in mind that lubrication can help.

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An Absolute Zero Of A Project

April 16, 2025 by Dan Maloney 12 Comments

How would you go about determining absolute zero? Intuitively, it seems like you’d need some complicated physics setup with lasers and maybe some liquid helium. But as it turns out, all you need is some simple lab glassware and a heat gun. And a laser, of course.

To be clear, the method that [Markus Bindhammer] describes in the video below is only an estimation of absolute zero via Charles’s Law, which describes how gases expand when heated. To gather the needed data, [Marb] used a 50-ml glass syringe mounted horizontally on a stand and fitted with a thermocouple. Across from the plunger of the syringe he placed a VL6180 laser time-of-flight sensor, to measure the displacement of the plunger as the air within it expands.

Data from the TOF sensor and the thermocouple were recorded by a microcontroller as the air inside the syringe was gently heated. Plotting the volume of the gas versus the temperature results shows a nicely linear relationship, and the linear regression can be used to calculate the temperature at which the volume of the gas would be zero. The result: -268.82°C, or only about four degrees off from the accepted value of -273.15°. Not too shabby.

[Marb] has been on a tear lately with science projects like these; check out his open-source blood glucose measurement method or his all-in-one electrochemistry lab.

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GK STM32 MCU-Based Handheld Game System

April 16, 2025 by Maya Posch 8 Comments

These days even a lowly microcontroller can easily trade blows with – or surpass – desktop systems of yesteryear, so it is little wonder that DIY handheld gaming systems based around an MCU are more capable than ever. A case in point is the GK handheld gaming system by [John Cronin], which uses an MCU from relatively new and very capable STM32H7S7 series, specifically the 225-pin STM32H7S7L8 in TFBGA package with a single Cortex-M7 clocked at 600 MHz and a 2D NeoChrom GPU.

Coupled with this MCU are 128 MB of XSPI (hexa-SPI) SDRAM, a 640×480 color touch screen, gyrometer, WiFi network support and the custom gkOS in the firmware for loading games off an internal SD card. A USB-C port is provided to both access said SD card’s contents and for recharging the internal Li-ion battery.

As can be seen in the demonstration video, it runs a wide variety of games, ranging from DOOM (of course), Quake, as well as Command and Conquer: Red Alert and emulators for many consoles, with the Mednafen project used to emulate Game Boy, Super Nintendo and other systems at 20+ FPS. Although there aren’t a lot of details on how optimized the current firmware is, it seems to be pretty capable already.

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Our hacker converts an old hard disk drive into a disc sander.

Making A Variable Speed Disc Sander From An Old Hard Drive

April 16, 2025 by John Elliot V 60 Comments

This short video from [ProShorts 101] shows us how to build a variable speed disc sander from not much more than an old hard drive.

We feel that as far as hacks go this one ticks all the boxes. It is clever, useful, and minimal yet comprehensive; it even has a speed control! Certainly this hack uses something in a way other than it was intended to be used.

Take this ingenuity and add an old hard drive from your junkbox, sandpaper, some glue, some wire, a battery pack, a motor driver, a power socket and a potentiometer, drill a few holes, glue a few pieces, and voilà! A disc sander! Of course the coat of paint was simply icing on the cake.

The little brother of this hack was done by the same hacker on a smaller hard drive and without the speed control, so check that out too.

One thing that took our interest while watching these videos is what tool the hacker used to cut sandpaper. Here we witnessed the use of both wire cutters and a craft knife. Perhaps when you’re cutting sandpaper you just have to accept that the process will wear out the sharp edge on your tool, regardless of which tool you use. If you have a hot tip for the best tool for the job when it comes to cutting sandpaper please let us know in the comments! (Also, did anyone catch what type of glue was used?)

If you’re interested in a sander but need something with a smaller form factor check out how to make a sander from a toothbrush! Continue reading “Making A Variable Speed Disc Sander From An Old Hard Drive” →

FLOSS Weekly Episode 829: This Machine Kills Vogons

April 16, 2025 by Jonathan Bennett No comments

This week, Jonathan Bennett chats with Herbert Wolverson and Frantisek Borsik about LibreQOS, Bufferbloat, and Dave Taht’s legacy. How did Dave figure out that Bufferbloat was the problem? And how did LibreQOS change the world? Watch to find out!

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SpaceMouse Destroyed For Science

April 16, 2025 by Fenix Guthrie 33 Comments

The SpaceMouse is an interesting gadget beloved by engineers and artists alike. They function almost like joysticks, but with six degrees of freedom (6DoF). This can make them feel a bit like magic, which is why [Thought Bomb Design] decided to tear one apart and figure out how it works.

The movement mechanism ended up being relatively simple; three springs soldered between two PCBs with one PCB being fixed to the base and the other moving in space. Instead of using a potentiometer or even hall effect sensor as you might expect from a joystick, the space mouse contained a set of six LEDs and light meters.

The sensing array came nestled inside a dark box made of PCBs. An injection molded plastic piece with slits would move to interrupt the light coming from the LEDs. The mouse uses the varying values coming from the light meter to decode Cartesian motion of the space mouse. It’s very simple and a bit hacky, just how we like it.

Looking for a similar input device, but want to take the DIY route? We’ve seen a few homebrew versions of this concept that might provide you with the necessary inspiration.

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Porting COBOL Code And The Trouble With Ditching Domain Specific Languages

April 16, 2025 by Maya Posch 80 Comments

Whenever the topic is raised in popular media about porting a codebase written in an ‘antiquated’ programming language like Fortran or COBOL, very few people tend to object to this notion. After all, what could be better than ditching decades of crusty old code in a language that only your grandparents can remember as being relevant? Surely a clean and fresh rewrite in a modern language like Java, Rust, Python, Zig, or NodeJS will fix all ailments and make future maintenance a snap?

For anyone who has ever had to actually port large codebases or dealt with ‘legacy’ systems, their reflexive response to such announcements most likely ranges from a shaking of one’s head to mad cackling as traumatic memories come flooding back. The old idiom of “if it ain’t broke, don’t fix it”, purportedly coined in 1977 by Bert Lance, is a feeling that has been shared by countless individuals over millennia. Even worse, how can you ‘fix’ something if you do not even fully understand the problem?

In the case of languages like COBOL this is doubly true, as it is a domain specific language (DSL). This is a very different category from general purpose system programming languages like the aforementioned ‘replacements’. The suggestion of porting the DSL codebase is thus to effectively reimplement all of COBOL’s functionality, which should seem like a very poorly thought out idea to any rational mind.

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