Custom Keyfob Fixes Mazda Design Mistake

May 24, 2021 by Bryan Cockfield 60 Comments

While Mazda has made some incredible advances in fuel efficient gasoline engines over the past few years, their design group seems to have fallen asleep at the wheel in the meantime, specifically in regards to the modern keyfob design. The enormous size and buttons on the side rather than the face are contrary to what most people need in a keyfob: small size and buttons that don’t accidentally get pressed. Luckily, though, the PCB can be modified with some effort.

This particular keyfob has a relatively simple two-layer design which makes it easy to see where the connections are made. [Hack ‘n’ Tink] did not need the panic button or status LED which allowed him to simply cut away a section of the PCB, but changing the button layout was a little trickier. For that, buttons were soldered to existing leads on the face of the board using 30-gage magnet wire and silicone RTV. From there he simply needed to place the battery in its new location and 3D print the new enclosure.

The end result is a much smaller form factor keyfob with face buttons that are less likely to accidentally get pressed in a pocket. He also made sure that the battery and button relocation wouldn’t impact the antenna performance. It’s a much-needed improvement to a small but crucial part of the car; the only surprise is that a company that’s usually on point with technology and design would flop so badly on such a critical component.

Thanks to [Brian] for the tip!

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Modifying Lights For DIY Ambiance

May 23, 2021 by Bryan Cockfield 13 Comments

The ESP32 and ESP8266 spread like wildfire a few years ago due to their small form factor, low price, and wireless capability. They didn’t just take over the DIY scene, though. Plenty of mass market products began to incorporate these tiny chips as well, which means that there are some interesting pre-made devices around that are ripe for modification. In this case, using an off-brand smart light bulb as a base for an semi-proprietary lighting setup.

The lighting in this build is a generic RGB light bulb with the ability to control its color over Wi-Fi. Since it has an ESP8266 chip in it, it can be made to work with Philips Hue lights with some minor modifications, allowing a much wider range of control than otherwise available. For this one, [Vadim] needed to pry open the bulb case to access the chip, then solder wires to it for reprogramming. It needed power during this step which meant plugging the resulting mess of wires back into a lamp socket, but after this step the new programming allows the bulb to be reprogrammed remotely.

After that step is complete, though, the generic bulb is ready for its inclusion into a Hue lighting system. In this case, [Vadim] is using diyHue, a Hue emulator that allows control of the bulbs without needing to use any cloud services, running on a BeagleBone. It’s a fairly comprehensive way of adding many different types and brands of bulbs to one system, and avoids any subscription models or the use of a cloud service, which is always something we can get behind.

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Send Old-Fashioned Pager Messages With New-Fashioned Hardware

May 18, 2021 by Bryan Cockfield 5 Comments

In a world of always-connected devices and 24/7 access to email and various social media and messaging platforms, it’s sometimes a good idea to take a step away from the hustle and bustle for peace of mind. But not too big of a step. After all, we sometimes need some limited contact with other humans, so that’s what [EverestX] set out to do with his modern, pocket-sized communication device based on pager technology from days of yore.

The device uses the POCSAG communications protocol, a current standard for pager communications that allows for an SMS-like experience for those still who still need (or want) to use pagers. [EverestX] was able to adapt some preexisting code and port it to an Atmel 32u4 microcontroller. With a custom PCB, small battery, an antenna, and some incredibly refined soldering skills, he was able to put together this build with an incredibly small footprint, slightly larger than a bottle cap.

Once added to a custom case, [EverestX] has an excellent platform for sending pager messages to all of his friends and can avoid any dreaded voice conversations. Pager hacks have been a favorite around these parts for years, and are still a viable option for modern communications needs despite also being a nostalgic relic of decades past. As an added bonus, the 32u4 microcontroller has some interesting non-pager features that you might want to check out as well.

Thanks to [ch0l0man] for the tip!

Scratch Built Tricycle Maximizes Fuel Efficiency

May 16, 2021 by Bryan Cockfield 27 Comments

While the bicycling community is welcoming an influx of electric bikes, there’s a group of tuners on the fringes that are still intent on strapping gas motors of all sizes to bicycles and buzzing down the roads in a loud and raucous fashion. Kits are readily available and are much cheaper than comparable e-bike kits, and with a little bit of work it’s possible to squeeze a lot of excitement from these small motors. With a lot of work, though, you might end up with something like this incredibly fuel efficient and fully customized reverse trike from [Paul Elkins].

The entire goal with this build was fuel efficiency, so the plan is to eventually enclose the vehicle in aerodynamic fairings, most likely using his favorite material, Coroplast. The frame itself is completely hand-made from square tube and welded by [Paul] himself to his own custom specifications. He bolts on a suspension and custom steering rack with levers to control the two front wheels, and the small engine and gas tank are attached to the back above the single drive wheel. The engine hadn’t been started in ten years, but once he got it all put together, it started right up and he was able to take his latest prototype out on the road for a test drive.

While the build isn’t completely finished, the video below (eleventh so far in the build log) is far enough along to show the fruits of years of [Paul]’s labor. It’s taken a while to get a design that worked like he wanted, but with this iteration, he finally has what he was looking for.

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3D Printing Espresso Parts

May 15, 2021 by Bryan Cockfield 28 Comments

Virtually any hobby has an endless series of rabbit holes to fall into, with new details to learn around every corner. This is true for beekeeping, microcontrollers, bicycles, and gardening (just to name a few), but those involved in the intricate world of coffee roasting and brewing turn this detail dial up to the max. There are countless methods of making coffee, all with devout followers and detractors alike, and each with its unique set of equipment. To explore one of those methods and brew a perfect espresso, [Eric] turned to his trusted 3D printer and some compressed gas cylinders.

An espresso machine uses high pressure to force hot water through finely ground coffee. This pressure is often developed with an electric pump, but there are manual espresso machines as well. These require expensive parts which can withstand high forces, so rather than build a heavy-duty machine with levers, [Eric] turned to compressed CO2 to deliver the high pressure needed.

To build the pressure/brew chamber, he 3D printed most of the parts with the exception of the metal basked which holds the coffee. The 3D printed cap needs to withstand around nine atmospheres of pressure so it’s reasonably thick, held down with four large bolts, and holds a small CO2 canister, relief valve, and pressure gauge.

To [Eric]’s fine tastes, the contraption makes an excellent cup of coffee at minimal cost compared to a traditional espresso machine. The expendable CO2 cartridges only add $0.15 to the total cost of the cup and for it’s simplicity and small size this is an excellent trade-off. He plans to improve on the design over time, and we can’t wait to see what he discovers. In the meantime, we’ll focus on making sure that our beans are of the highest quality so they’re ready for that next espresso.

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Reverse-Engineering An Unknown Microcontroller In E Ink Displays

May 15, 2021 by Bryan Cockfield 11 Comments

For a monochrome display where refresh rate isn’t particularly important, there’s almost no better option than an E Ink display. They’re available in plenty of sizes and at various price points, but there’s almost no option cheaper than repurposing something mass-produced and widely available like an E Ink (sometime also called eInk or ePaper) price tag. At least, once all of the reverse engineering is complete.

[Dmitry Grinberg] has been making his way through a ton of different E Ink modules, unlocking their secrets as he goes. In this case he set about reverse engineering the unknown microcontroller on the small, cheap display show here. Initial research showed an obscure chip from the ZBS24x family, packaged with a SSD1623L2 E Ink controller. From there, he was able to solder to the communications wires and start talking to the device over ISP.

This endeavor is an impressive deep dive into the world of microcontrollers, from probing various registers to unlocking features one by one. It’s running an 8051 core so [Dmitry] gives a bit of background to help us all follow along, though it’s still a pretty impressive slog to fully take control of the system.

If you happen to have one of these price tags on hand it’s an invaluable resource to have to reprogram it, but it’s a great read in general as well. On the other hand, if you’re more interested in reverse-engineering various displays, take a look at this art installation which spans 50 years of working display technologies.

Random Robot Makes Random Art

May 14, 2021 by Bryan Cockfield 4 Comments

For the price of a toothbrush and a small motor with an offset weight, a bristlebot is essentially the cheapest robot that can be built. The motor shakes the toothbrush and the bristle pattern allows the robot to move, albeit in a completely random pattern. While this might not seem like a true robot that can interact with its environment in any meaningful way, [scanlime] shows just how versatile this robot – which appears to only move randomly – can actually be used to make art in non-random ways.

Instead of using a single bristlebot for the project, three of them are built into one 3D printed flexible case where each are offset by 120°, and which can hold a pen in the opening in the center. This allows them to have some control on the robot’s direction of movement. From there, custom software attempts to wrangle the randomness of the bristlebot to produce a given image. Of course, as a bristlebot it is easily subjected to the whims of its external environment such as the leveling of the table and even the small force exerted by the power/communications tether.

With some iterations of the design such as modifying the arms and control systems, she has an interesting art-producing robot that is fairly reliable for its inherently random movements. For those who want to give something like this a try, the code for running the robot and CAD files for 3D printing the parts are all available on the project’s GitHub page. If you’re looking for other bristlebot-style robots that do more than wander around a desktop, be sure to take a look at this line-following bristlebot too.

Thanks to [johnowhitaker] for the tip!

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