Author: Dan Maloney

3373 Articles

Shop-Made Fixture Turns Out Dream Welds

November 10, 2017 by 14 Comments

You can tell a lot about a person by the company they keep, and you can tell a lot about a craftsman by the tools and jigs he or she builds. Whether for one-off jobs or long-term use, these ad hoc tools, like this tubing rotator for a welding shop, help deliver results beyond the ordinary.

What we appreciate about [Delrin]’s tool is not how complex it is — with just a motor from an old satellite dish and a couple of scooter wheels, it’s anything but complicated. What we like is that to fabricate some steering links, each of which required three passes of TIG welding to attach a threaded bung to the end of a rod, [Delrin] took the time to build just the tool for the job. The tools slowly rotates the rod, letting the welder keep the torch in one position as the workpiece moves under it. The grounding method is also simple but clever — just a wide strap of braid draped over the rod. The result is some of the prettiest and most consistent welds we’ve seen in a while, and with an order for 28 steering links, it ought to be a huge time saver.

It may be time for a little more TIG welding love around here. Sure, we’ve covered the basics of oxy-acetylene welding, and even talked about brazing aluminum. Perhaps your humble Hackaday writer will take the plunge into a new TIG welder and report from a newbie’s perspective. You know, for science.

[via r/welding]

Hacking When It Counts: Prison Locksmithing

November 10, 2017 by 28 Comments

In 1978, Tim Jenkin was a man living on borrowed time, and he knew it. A white South African in his late 20s, he had been born into the apartheid system of brutally enforced racial segregation. By his own admission, he didn’t even realize in his youth that apartheid existed — it was just a part of his world. But while traveling abroad in the early 1970s he began to see the injustice of the South African political system, and spurred on by what he learned, he became an activist in the anti-apartheid underground.

Intent on righting the wrongs he saw in his homeland, he embarked on a year of training in London. He returned to South Africa as a propaganda agent with the mission to spread anti-apartheid news and information to black South Africans. His group’s distribution method of choice was a leaflet bomb, which used a small explosive charge to disperse African National Congress propaganda in public places. Given that the ANC was a banned organization, and that they were setting off explosives in a public place, even though they only had a few grams of gunpowder, it was inevitable that Jenkin would be caught. He and cohort Steven Lee were arrested, tried and convicted;  Jenkin was sentenced to 12 years in prison, while Lee got eight.

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Hackaday Prize Entry: Reflowduino, The Open Source Reflow Oven Controller

November 7, 2017 by 34 Comments

Face it — you want a reflow oven. Even the steadiest hands and best eyes only yield “meh” results with a manual iron on SMD boards, and forget about being able to scale up to production. But what controller should you use when you build your oven, and what features should it support? Don’t worry — you can have all the features with this open source reflow oven controller.

Dubbed the Reflowduino for obvious reasons, [Timothy Woo]’s Hackaday Prize entry has everything you need in a reflow oven controller, and a few things you never knew you needed. Based on an ATMega32, the Reflowduino takes care of the usual tasks of a reflow controller, namely running the PID loop needed to accurately control the oven’s temperature and control the heating profile. We thought the inclusion of a Bluetooth module was a bit strange at first, but [Timothy] explains that it’s a whole lot easier to implement the controller’s UI in software than in hardware, and it saves a bunch of IO on the microcontroller. The support for a LiPo battery is somewhat baffling, as the cases where this would be useful seem limited since the toaster oven or hot plate would still need a mains supply. But the sounder that plays Star Wars tunes when a cycle is over? That’s just for fun.

Hats off to [Timothy] for a first-rate build and excellent documentation, which delves into PID theory as well as giving detailed instructions for every step of the build. Want to try lower-end reflow? Pull out a halogen work light, or perhaps fire up that propane torch.

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Sferics, Whistlers, And The Dawn Chorus: Listening To Earth Music On VLF

November 6, 2017 by 19 Comments

We live in an electromagnetic soup, bombarded by wavelengths from DC to daylight and beyond. A lot of it is of our own making, especially further up the spectrum where wavelengths are short enough for the bandwidth needed for things like WiFi and cell phones. But long before humans figured out how to make their own electromagnetic ripples, the Earth was singing songs at the low end of the spectrum. The very low frequency (VLF) band abounds with interesting natural emissions, and listening to these Earth sounds can be quite a treat.

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Repair Job Fixes Compressor, Gets It Online

November 5, 2017 by 35 Comments

We’ll never cease to be amazed at the things people try to put on the Internet of Things. Some are no-brainers, like thermostats, security cameras, and garage door openers. Others, like washing machines and refrigerators, are a little on the iffy side, but you can still make a case for them. But an IoT air compressor? What’s the justification for such a thing?

As it turns out, [Boris van Galvin] had a pretty decent reason for his compressor hacks, and it appears that the IoT aspect was one of those “why not?” things. Having suffered the second failure of his compressor’s mechanical pressure switch in a year, and unwilling to throw good money after the $120 that went into replacing the first contactor, [Boris] looked for a cheaper and more interesting way to control the compressor. An ESP8266 dev board made interfacing the analog pressure sensor a snap, and while he was at it, [Boris] added a web interface with a nice graphical air pressure gauge and some on-off controls. Now he can set the pressure using his phone and switch it off in the middle of the night without going outside. That’s an IoT win right there.

No air compressor? No worries — build your own from an old fridge. The non-IoT kind, preferably.

Hybrid Interface Brings Touchscreen To Rigol Scope

November 3, 2017 by 7 Comments

With pervasive smartphones and tablets, the touch interface is assumed for small LCD screens, and we’ve likely all poked and pinched at some screen, only to find it immune to our gestures. Manufacturers have noticed this and begun adding touch interfaces to instruments like digital oscilloscopes, but touch interfaces tend to be an upgrade feature. But thanks to this hybrid oscilloscope touchscreen interface, even the low-end scopes can get in on the action.

It only makes sense that [Matt Heinz] started with one of the most hackable scopes for this build, which was his Master’s thesis project. Using an Android tablet as an auxiliary interface, [Matt] is able to control most of the main functions of the scope remotely. Pinching and expanding gestures are interpreted as horizontal and vertical scaling, while dragging the displayed waveform changes its position and controls triggering. While it’s not a true touchscreen scope, the code is all open source, so can a true aftermarket Rigol touchscreen be far away?

Rigol hacks abound here — you can talk to them in Linux, increase the bandwidth, or just get a look at their guts.

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[Jeri] Builds A Magnetic Loop Antenna

November 1, 2017 by 43 Comments

Most new hams quickly learn that the high-frequency bands are where the action is, and getting on the air somewhere between 40- and 160-meters is the way to make those coveted globe-hopping contacts. Trouble is, the easiest antennas to build — horizontal center-fed dipoles — start to claim a lot of real estate at these wavelengths.

So hacker of note and dedicated amateur radio operator [Jeri Ellsworth (AI6TK)] has started a video series devoted to building a magnetic loop antenna for the 160- and 80-meter bands. The first video, included after the break, is an overview of the rationale behind a magnetic loop. It’s not just the length of the dipole that makes them difficult to deploy for these bands; as [Jeri] explains, propagation has a lot to do with dipole height too. [Jeri] covers most of the mechanical aspects of the antenna in the first installment; consuming a 50-foot coil of 3/4″ copper tubing means it won’t be a cheap build, but we’re really looking forward to seeing how it turns out.

We were sorry to hear that castAR, the augmented reality company that [Jeri] co-founded, shut its doors back in June. But if that means we get more great projects like this and guided tours of cool museums to boot, maybe [Jeri]’s loss is our gain?

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