Move Over Red Bull, Hot Wire Foam Cutter Now Gives You Wings

May 14, 2015 by Rich Bremer 13 Comments

Not many people will argue with flying RC airplanes is super fun. One big bummer is when a crash damages a part beyond repair. Sure, the RC pilot could keep buying replacement parts but doing so will add up after a while. RC plane builder and general guy with a cool name, [HuckinChikn], decided to build a hot wire foam cutter so making replacement wings would be quick and cheap.

The actual hot wire part is nothing special, just some wire pulled taut across a frame and a 24 vdc power supply pumping out current and heating the wire so it melts any foam in its path. The unique part of the build is that one side of the hot wire frame is secured in place and only allowed to pivot about that point. The other side of the frame traces an airfoil-shaped pattern. This setup allows [HuckinChikn] to make tapered wings. The difference between a straight wing and a tapered wing is similar to that of a cylinder and cone.

Check out the video after the break for a quick demonstration how easy it is to make a wing when you have the right tool!

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DIY Wave Energy Reclamation, Not So Complicated After All

May 13, 2015 by Rich Bremer 27 Comments

We humans are becoming more aware every day that we need to reduce our fossil fuel dependence and move to more renewable methods lest we make the earth a less-desirable place to live. The sun is here today, and it will be tomorrow, harness that energy is one solution. There are places that are commonly windy, we can harness that energy too. [Jonathan] and [Ellen] set out to harness that wind energy but not in the traditional wind-turbine way. Wind creates ocean waves and the pair set out to recover some of that wave energy. They built a proof of concept and they did it on a budget with a side of DIY-style, to boot!

The device consists of a raft, with magnets attached to a sheet metal ruler standing on end. As you would expect, this ruler is flexible and the mass of the magnets easily sways back and forth as waves pass. The magnets move through stationary wire coils and as they do, creating an electrical current in the coils. The output of the coils is AC, which is then rectified to pulsed DC using several diodes and smoothed even further by some capacitors. The two DC outputs are then connected in series to double the voltage to 5 with a max current of about 20mA.

For this experiment the generator powers a modified smoke alarm which keeps burglars away from a coral reef. But the team could see this powering lights on buoys or low-power sensors. What would you use it for?

DIY Concrete Mixing Wheelbarrow Made From Recycled Parts

May 11, 2015 by Rich Bremer 18 Comments

[Dan] had a bunch of concrete mixing to do. Sure, it was possible to stand there and mix concrete and water in a wheelbarrow for hours and hours but that sounds like a tedious task. Instead, [Dan] looked around the shop to see if he had parts available to make a concrete mixer. As you may have guessed, he did. Instead of stopping at just a concrete mixer, he decided to make a concrete mixing wheelbarrow!

The frame is built out of plywood left over from a past canoe project. The frame holds a mixing barrel that was also hanging around the shop. From the photo, the drive system looks simple but it is not. First, the small motor pulley spins a larger pulley that is in-line with the barrel. Gearing down the drive this way increases torque available to spin the barrel, and that gear reduction is necessary to spin the heavy concrete slowly. What you can’t see is a planetary gear system that gears down the drive train again. The gears are cut out of plywood and were designed in this Gear Generator program. The sun (center) gear of the planetary setup is supported by another scavenged part, a wheel bearing from a Chevy minivan.

Now [Dan] can mix all the concrete he wants, wheel it over and dump it wherever he needs it. With the exception of the drive belt and some miscellaneous hardware, all the parts were recycled.

Observercade, Portable MAME System Of The Future.

May 11, 2015 by Rich Bremer 8 Comments

[GarageMonkeySan] wrote in to tell us about his latest project. It’s a MAME arcade emulator, but not just any MAME arcade emulator, it is housed in a briefcase. And if that was not interesting enough, it was built in the style of the TV Show “Fringe”, specifically like the Observer briefcases. He calls it the Observercade.

The hard-shelled Samsonite briefcase was taken apart to assess the best way to move forward. A Sintra frame was added to the top half of the briefcase and would hold a scavenged laptop LCD screen. A monitor faceplate was then made from 1/16″ polystyrene sheet to fill the gap around the screen.

The bottom half of the case holds the remaining electronics, which consists of a Raspberry Pi Model B (running RetroPie), power supply, speakers and LCD driver board. They are all mounted to the bottom of the control surface which also supports the controller joystick and buttons. Notice that the buttons are labeled in Observer symbols. These symbols are as accurate as possible roughly translating to ‘credit’, ‘player’… etc. This is a wonderfully done project that shows [GarageMonkeySan] pays extreme attention to detail.

If the Observercade rings a bell, you may be remembering the project that gave [GarageMonkeySan] his inspirations: the Briefcade.

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Router Fixture For Radiusing Guitar Fretboards

May 10, 2015 by Rich Bremer 18 Comments

Unless you’ve been up close and personal with a guitar, it’s easy to miss that the fretboard (where a guitar player presses on the strings) is not flat. There is a slight curve, the amount of which varies with the type and brand of guitar. There are even guitars with fretboards that have a compound radius that changes from one end to the other.

[Mike] is a guitar builder and needed a way to radius his own fretboards. He did what any other DIYer would, he designed and built a tool to do exactly what he needed. The fretboard radius cutting fixture consists of a new large router base that has a curved bottom. This base rests on two metal pipes and can slide both back and forth in addition to along the new base’s curve. The flat fretboard blank is secured to the fixture below the router and is slowly nibbled away at using a standard straight flute router bit. A little sanding later and [Mike] will be able to keep moving forward on his guitar builds.

DIY AC For The Hot Shop

May 10, 2015 by Rich Bremer 74 Comments

Working out in the shop is usually super fun but if it’s summertime, watch out, it can get hot! We’ve all been there and we’ve all wished we could do something about it. Well, woodworker and general DIYer [April] has stepped up to the plate and built a portable low-buck AC unit to cool her shop down to an acceptable temperature.

The unit is very simple and starts off with an old thrift store cooler. A hole is cut in the back of the cooler to make room for a fan that is directed to blow air inside the cooler and across blocks of ice. The air cools down as it passes over the ice and leaves out the top of the cooler through five 90-degree PVC elbows. After all the inlets and outlets were caulked, the entire unit was given a monochromatic black paint job.

[April] says you can feel the cool air blowing from about 5 feet away from the unit. She has measured the output air temperature to be 58-62ºF. If using loose ice cubes, the unit will work for 2-3 hours. Freezing milk jugs full of water gets about 5 hours of use.

New Cross Bladed Axe Not For Cosplay Or Larping

May 9, 2015 by Rich Bremer 51 Comments

Firewood aficionado and general axing enthusiast [KH4] likes to cut and split his own fire wood. To burn a tree trunk sized piece of wood efficiently, it has to be split into 4 smaller pieces. [KH4] does this with 3 axe swings, the first splitting the main log in 2, then splitting each half in half again. Although he likes swinging the mighty axe, he still would like to increase the efficiency of each swing.

Well he’s done it! This is accomplished by making a Cross Bladed Axe that has an X-shaped head. Each axe swing should split a log into 4 pieces. That results in 66% less swings for the same amount of wood split!

This projected started with two spare axe heads. One was cut in half with an angle grinder. The two axe head halves were then ground down so that they match the contour of the original axe head. Once the fit was good, the welder was broken out and all 3 axe head pieces were combined into one beastly mass.

After the new head was polished and sharpened, it was re-assembled a new hickory handle. We have to say, the end product looks pretty awesome. There’s a video after the break of this axe in action. Check it out!

Have you ever seen how these axe heads used to be manufactured?

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