Turning A Lada Into An EV With 50 Cordless Drills, Because Why Not?

January 1, 2025 by Donald Papp 45 Comments

[Garage 54] is no stranger to vehicle-related projects of the “because why not?” variety, and their latest is using 50 cordless drills combined into a monstrous mega-motor to turn a gutted (and extended) Lada into an electric vehicle (EV).

Doing this leans on some of [Garage 54]’s earlier projects, such as replacing the aforementioned Lada’s engine block with a frame containing sixteen chainsaws. That means they don’t need to start completely from scratch, and have a frame design that can drop into the vehicle once the “engine” is constructed.

Fifty cordless drills won’t set any efficiency records for EV engines, but it’s got a certain style.

Here’s what’s in the new engine: each of the drills has its chuck replaced with an aluminum pulley, and belts connect each group of drills to an output shaft. Ideally, every drill motor would run at the same time and at exactly the same speed, but one works with what they have. [Garage 54] originally worked to synchronize the drills by interfacing to each drill’s motor control board, but eventually opted to simply bypass all controls and power each drill’s motor directly from the batteries. Initial tests are done by touching bare cable ends with a turned-away face and squinted eyes, but we expect “Just A Big Switch” to end up in the final assembly.

It looks wild and we can think of more than a few inefficiencies present in a system like this, but the output shaft does turn and torque is being transferred, so the next step is interfacing to the car’s factory gearbox.

If it powers the car in any meaningful way, that Lada might very well become the world’s most gloriously hacked-together EV. And hey, if the power output of the EV motor is disappointing, you can just make your own.

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Porting Dragon’s Lair To The Game Boy Color Was A Technical Triumph

December 28, 2024 by Donald Papp 5 Comments

If you remember the 80s arcade game Dragon’s Lair, you probably also remember it was strikingly unlike anything else at the time. It didn’t look or play like anything else. So it might come as a surprise that it was ported to Nintendo’s Game Boy Color, and that took some doing!

Dragon’s Lair used LaserDisc technology, and gameplay was a series of what we’d today call quick-time events (QTE). The player essentially navigated a series of brief video clips strung together by QTEs. Generally, if the player chose correctly the narrative would progress. If they chose poorly, well, that’s what extra lives (and a stack of quarters) were for.

More after the break!

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Watch A 3D Scan Become A Car Body Model

December 20, 2024 by Donald Papp 1 Comment

Not all 3D scanning is alike, and the right workflow can depend on the object involved. [Ding Dong Drift] demonstrates this in his 3D scan of a project car. His goal is to design custom attachments, and designing parts gets a lot easier with an accurate 3D model of the surface you want to stick them on. But it’s not as simple as just scanning the whole vehicle. His advice? Don’t try to use or edit the 3D scan directly as a model. Use it as a reference instead.

Rather than manipulate the 3D scan directly, a better approach is sometimes to use it as a modeling reference to fine-tune dimensions.

To do this, [Ding Dong Drift] scans the car’s back end and uses it as a reference for further CAD work. The 3D scan is essentially a big point cloud and the resulting model has a very high number of polygons. While it is dimensionally accurate, it’s also fragmented (the scanner only captures what it can see, after all) and not easy to work with in terms of part design.

In [Ding Dong Drift]’s case, he already has a 3D model of this particular car. He uses the 3D scan to fine-tune the model so that he can ensure it matches his actual car where it counts. That way, he’s confident that any parts he designs will fit perfectly.

3D scanning has a lot of value when parts have to fit other parts closely and there isn’t a flat surface or a right angle to be found. We saw how useful it was when photogrammetry was used to scan the interior of a van to help convert it to an off-grid camper. Things have gotten better since then, and handheld scanners that make dimensionally accurate scans are even more useful.

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Pulling Backward To Go Forward: The Brennan Torpedo Explained

December 17, 2024 by Donald Papp 16 Comments

The Brennan torpedo, invented in 1877 by Louis Brennan, was one of the first (if not the first) guided torpedoes of a practical design. Amazingly, it had no internal power source but it did have a very clever and counter-intuitive mode of operation: a cable was pulled backward to propel the torpedo forward.

If the idea of sending something forward by pulling a cable backward seems unusual, you’re not alone. How can something go forward faster than it’s being pulled backward? That’s what led [Steve Mould] to examine the whole concept in more detail in a video in a collaboration with [Derek Muller] of Veritasium, who highlights some ways in which the physics can be non-intuitive, just as with a craft that successfully sails downwind faster than the wind.

The short answer is gearing, producing more force on the propeller by pulling out lots of rope.

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PCB Motor Holds Fast, Even After 1.6 Billion Spins

December 17, 2024 by Donald Papp 32 Comments

If you aren’t up to date with [Carl Bugeja]’s work with tiny brushless PCB motors, his summary video of his latest design and all the challenges it involved is an excellent overview.

Back in 2018 we saw [Carl]’s earliest versions making their first spins and it was clear he was onto something. Since then they have only improved, but improvement takes both effort and money. Not only does everything seemingly matter at such a small scale, but not every problem is even obvious in the first place. Luckily, [Carl] has both the determination and knowledge to refine things.

Hardware development is expensive, especially when less than a tenth of a millimeter separates a critical component from the junk pile.

The end result of all the work is evident in his most recent test bed: an array of twenty test motors all running continuously at a constant speed of about 37,000 RPM. After a month of this, [Carl] disassembled and inspected each unit. Each motor made over 53 million rotations per day, closing out the month at over 1.6 billion spins. Finding no sign of internal scratches or other damage, [Carl] is pretty happy with the results.

These motors are very capable but are also limited to low torque due to their design, so a big part of things is [Carl] exploring and testing different possible applications. A few fun ones include a wrist-mounted disc launcher modeled after a Spider-Man web shooter, the motive force for some kinetic art, a vibration motor, and more. [Carl] encourages anyone interested to test out application ideas of their own. Even powering a micro drone is on the table, but will require either pushing more current or more voltage, both of which [Carl] plans to explore next.

Getting any ideas? [Carl] offers the MotorCell for sale to help recover R&D costs but of course the design is also open source. The GitHub repository contains code and design details, so go ahead and make them yourself. Or better yet, integrate one directly into your next PCB.

Got an idea for an application that would fit a motor like this? Don’t keep it to yourself, share in the comments.

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3D Printed Blaster Does It With Compliant Components

December 17, 2024 by Donald Papp 20 Comments

The ease of integrating bendy parts into designs is one of 3D printing’s strengths. A great example of this is [uhltimate]’s six-shot blaster which integrates several compliant mechanisms. The main blaster even prints in one piece, so there’s not even any assembly required.

The ergonomics are unconventional, but the design is pretty clever.

The blaster itself has three main parts: the trigger, the sear, and the striker. Each of them rely on compliant mechanisms in order to function. The user pulls back the trigger, which hooks into and pulls back the striker. When the trigger is pulled back far enough, the sear releases the striker. This zips forward and slams into a waiting projectile, sending it flying.

The other interesting part is the projectiles and magazine in which they sit. The magazine fits onto the front of the blaster and pulling the trigger allows the magazine to drop down, putting the next projectile into firing position. After the final round is fired, the empty magazine falls away. It’s a pretty clever design, even if the ergonomics are a little unusual and it relies on gravity in order to feed. Tilt it too far sideways or upside down, and it won’t load properly.

We’ve seen compliant mechanisms used for projectile firing before, but this design really raises the bar in the way it does more than just firing the striker.

3D printing allows rapid iteration of designs, which makes devices that rely on compliant mechanisms much easier to develop and fine-tune.

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How The Lost Mystery Pigment ‘Maya Blue’ Got Recreated

December 14, 2024 by Donald Papp 16 Comments

A distinct blue pigment reminiscent of turquoise or a clear sky was used by the ancient Maya to paint pottery, sculptures, clothing, murals, jewelry, and even human sacrifices. What makes it so interesting is not only its rich palette — ranging from bright turquoise to a dark greenish blue — but also its remarkable durability. Only a small number of blue pigments were created by ancient civilizations, and even among those Maya blue is unique. The secret of its creation was thought to be lost, until ceramicist and artist [Luis May Ku] rediscovered it.

Maya blue is not just a dye, nor a ground-up mineral like lapis lazuli. It is an unusual and highly durable organic-inorganic hybrid; the result of a complex chemical process that involves two colorants. Here is how it is made: Indigotin is a dye extracted from ch’oj, the Mayan name for a specific indigenous indigo plant. That extract is combined with a very specific type of clay. Heating the mixture in an oven both stabilizes it produces a second colorant: dehydroindigo. Together, this creates Maya blue.

The road to rediscovery was not a simple one. While the chemical makeup and particulars of Maya blue had been known for decades, the nuts and bolts of actually making it, not to mention sourcing the correct materials, and determining the correct techniques, was a long road. [May] made progress by piecing together invaluable ancestral knowledge and finally cracked the code after a lot of time and effort and experimentation. He remembers the moment of watching a batch shift in color from a soft blue to a vibrant turquoise, and knew he had finally done it.

Before synthetic blue pigments arrived on the scene after the industrial revolution, blue was rare and highly valuable in Europe. The Spanish exploitation of the New World included controlling Maya blue until synthetic blue colorants arrived on the scene, after which Maya blue faded from common knowledge. [May]’s rediscovered formula marks the first time the world has seen genuine Maya blue made using its original formula and methods in almost two hundred years.

Maya blue is a technological wonder of the ancient world, and its rediscovery demonstrates the resilience and scientific value of ancestral knowledge as well as the ingenuity of those dedicated to reviving lost arts.

We’re reminded that paints and coatings have long been fertile ground for experimentation, and as an example we’ve seen the success people had in re-creating an ultra-white paint that actually has a passive cooling effect.