Planning Custom Aluminum Enclosures With OpenSCAD

December 26, 2021 by Tom Nardi 20 Comments

We’ve seen a number of projects over the years that let you create custom enclosures using OpenSCAD, and for good reason. The parametric CAD tool is ideal for generating 3D models based on user-adjustable variables, and if you leverage its integrated Customizer, producing a bespoke box is as easy as moving some sliders around. The resulting files get sent off to the 3D printer, and you’re set. But what if you’re looking for a custom enclosure that’s not so…plastic?

In that case, AlClosure by [0xPIT] might be the answer. Rather than generating STL files intended for your 3D printer, the code is written to help you design an enclosure made from aluminum sheets. The top and bottom panels are intended to be cut from 1.5 mm – 2.5 mm sheets, while the sides are made from thicker 5 mm – 8 mm stock to accept a machined pocket that holds the front and rear inserts.

Since it’s OpenSCAD, much of the design is governed by variables which you can tweak. Obviously the outside dimensions of the enclosure can be changed in a flash, but it’s just as easy to modify the thickness of the aluminum sheet being used, or the size of the screw holes. [0xPIT] has also done a great job of documenting the code itself, so you’ll know exactly what you’re modifying.

Obviously, you’ll need the ability to cut and machine aluminum to actually utilize this project. The code itself is really just a way to conceptualize the design and get your dimensions figured out ahead of time. But as we were recently reminded by the keynote presentation [Jeremy Fielding] gave at the 2021 Remoticon, this sort of early prototyping can often save you a lot of headaches down the line.

Keynote Video: Jeremy Fielding Wants To Help You Get Moving

December 23, 2021 by Tom Nardi 7 Comments

For many DIY hardware projects, the most movement it’s likely to see is when we pick the assembled unit up off the workbench and carry it to wherever it’s destined to spend the rest of its functional life. From weather sensors to smart mirrors, there’s a huge array of devices that don’t need to move one millimeter to function. But eventually, you’re likely to run into a project that’s a bit more dynamic. Maybe you’d like to motorize your window shades, or go all out and build a remote controlled rover. With these more active designs comes a whole slew of new problems you may never have encountered before.

Luckily for us, folks like Jeremy Fielding are out there and willing to share their knowledge. In his fascinating presentation for the 2021 Hackaday Remoticon, Building Hardware that Moves: the Fundamentals that Everyone Should Know, he took viewers on a whirlwind tour of what he’s learned about designing and building complex machines from his years of professional experience. Whether its a relatively simple articulated workbench for the shop, a gargantuan earthmoving machine, or a high-dexterity robotic arm, each project he’s worked on has presented unique challenges that needed to be solved.

Not all of Jeremy’s machines will fit in your average workshop.

A lot of the projects that Jeremy has worked on are on a much larger scale than what your average hobbyist is ever going to run into. When there’s an arrow pointing out the tiny human in a picture of you and the machine you’re currently working on, you know things are getting serious. But as anyone who’s watched his YouTube videos knows, he’s got a real knack for taking these high-level concepts and distilling them into something more digestible for the home gamer.

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All Hail Your New Giant 555 Timer Overlord

December 20, 2021 by Tom Nardi 46 Comments

You asked for it, and now you’ve got it. It’s taken more than a decade of accumulated complaining, but this gigantic 555 timer IC has finally gathered enough psychokinetic energy to take corporeal form and demand fealty from the readers of Hackaday.

Or not. The less exciting explanation is that creator [Rudraksha Vegad] was looking for a way to combine his interests in discrete electronic components and woodworking. The result is an incredible build that’s more than just a conversation starter; this desktop-sized version of the iconic integrated timer circuit is fully functional. You can even hook it up to a breadboard, assuming you’ve got some alligator clips handy.

Lifting the lid on this wooden “chip” uncovers an intricate hand-wired array of discrete components that stand in for the microscopic goings on inside the real thing. He’s even gone through the trouble of recreating the symbols for the comparators and flip-flops that you’d see in a diagram of a 555 using wooden shapes to elevate their respective components. It might not fit the classical definition, but surely this must count as some form of circuit sculpture.

[Rudraksha] credits several other projects for not just inspiring him to create his own mega 555, but for helping him wrap his head around the internal workings of everyone’s favorite IC. Using components he salvaged from old hardware, he says the project ended up being very educational for him. These days, when most makers are more likely to reach for a microcontroller than a logic chip, spending some quality time with transistors and passives can be quite illuminating.

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SDR Toolkit Bends Weather Station To Hacker’s Whims

December 17, 2021 by Tom Nardi 9 Comments

We probably don’t have to tell most Hackaday readers why the current wave of low-cost software defined radios (SDRs) are such a big deal for hackers looking to explore the wide world of wireless signals. But if you do need a refresher as to what kind of SDR hardware and software should be in your bag of tricks, then this fantastically detailed account from [RK] about how he hacked his La Crosse WS-9611U-IT weather station is a perfect example.

Looking to brush up his radio hacking skills, [RK] set out to use the ADALM-PLUTO software defined radio from Analog Devices to intercept signals between the La Crosse base station and its assorted wireless sensors. He notes that a $20 USD RTL-SDR dongle could do just as well if you only wanted to receive, but since his ultimate goal was to spoof a temperature sensor and introduce spurious data into the system, he needed an SDR that had transmit capabilities.

No matter your hardware, Universal Radio Hacker (URH) is the software that’s going to be doing the heavy lifting. In his write-up, [RK] walks the reader through every step required to find, capture, and eventually decode the transmissions coming from a TX29U wireless temperature sensor. While the specifics will naturally change a bit depending on the device you’re personally looking to listen in on, the general workflow is going to be more or less the same.

In the end, [RK] is not only able to receive the data coming from the wireless sensors, but he can transmit his own spoofed data that the weather station accepts as legitimate. Getting there took some extra effort, as he had to figure out the proper CRC algorithm being used. But as luck would have it, he found a Hackaday article from a couple years back that talked about doing exactly that, which help put him on the right path. Now he can make the little animated guy on the weather station’s screen don a winter coat in the middle of July. Check out the video below for a demonstration of this particular piece of radio prestidigitation.

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Weather Station Dumps CR2032 Cells, Gains 18650

December 16, 2021 by Tom Nardi 34 Comments

Despite the fact that we’re rapidly approaching the year 2022, there are still an incredible number of gadgets out there that you’re expected to power with disposable batteries. Sure you can buy rechargeable stand-ins that come in the various shapes and sizes of the traditional alkaline cells, but that’s a stopgap at best. For some, if a new gadget doesn’t feature an internal Li-ion battery and standardized USB charging, it’s a non-starter.

[Danilo Larizza] is one of those people. Bothered by the fact that his Oregon Scientific weather station required a pair of CR2032 coin cells, he set out to replace them with an integrated rechargeable solution. The conversion ending up being easier to implement than he initially expected, and by his calculations, his solution should keep the unit up and running for nearly 40 days before needing to be topped off with a standard USB charger.

The first step was determining how much power it actually took to run the weather station. Although the two CR2032 cells were wired in series, and therefore providing a nominal 6 V, he determined through experimentation with a bench power supply that it would run on as little as 3.2 volts. This coincides nicely with the voltage range for a single 18650 cell, and meant he didn’t need to add a boost converter into the mix. He notes the weather station does flash a “Low Battery” warning most of the time now, but that seems a fair price to pay.

Confident in the knowledge that the weather station could happily run with an 18650 cell connected in place of the original CR2032s, all [Danilo] needed to do was figure out a way to charge the battery up from time to time. To that end, he reached for a common TP4056 module. This handy little board is a great match for 18650 cells, and is so cheap that there’s really no excuse not to have a few of them kicking around your parts bin. You never know when you might need to teach an old gadget new tricks.

A Slim 7400 Logic VGA Board For All Your Retro Needs

December 14, 2021 by Tom Nardi 10 Comments

Over the years we’ve seen a number of hackers generate VGA with 74xx logic chips, but they’ve generally not been the most practical of builds. Often put together as part of a competition or purely for the challenge, these circuits are usually implemented in a mass of jumper wires and often take up multiple breadboards. Not exactly something you can toss in a drawer when you’re done with it.

But the Vectron VGA Plus, created by prolific hacker [Nick Bild], manages to improve on things considerably. Designed specifically to be smaller and simpler than its predecessors, the custom PCB contains far fewer chips than we’re used to seeing for this kind of thing. At the same time it provides a handy header row along the bottom that allows the user to connect whatever they’re working on, from microcontrollers to retro computers.

When your breadboard looks like this, it’s time for a PCB.

It looks like the PCB could still be shrunk down considerably if you’re really looking to maximize desk space, but we imagine for his purposes, [Nick] felt this was more than compact enough. Especially when you look at what the same circuit looked like during the breadboard phase. Yikes.

So, what did it take to simplify this 640 x 480 VGA interface? The short answer is adding more RAM. Wherever possible, dedicated hardware was replaced with software operations that could be performed by the externally connected device. [Nick] has provided some sample code for the Arduino that lets the microcontroller push data into the board’s memory and take control.

We can trace the origins of this project back a few years, to when [Nick] was working on adding an LCD to his homebrew 6502 computer. A few months later he put together the earlier version of this board, the Vectron VGA, before switching gears and handing VGA generation duty over to a FPGA. We’re excited to see the next evolution of this project, and given the track record of this particular hacker, we shouldn’t have to wait long before it hits our inbox.

Teardown: Verizon AC791L Jetpack 4G Mobile Hotspot

December 14, 2021 by Tom Nardi 24 Comments

The saying “time and tide wait for no man” is usually used as a verbal kick in the pants, a reminder that sometimes an opportunity must be seized quickly before it passes by. But it can also be interpreted as a warning about the perpetual march of time and how it impacts the world around us. In that case, we would do well to add cellular technology to the list of proverbial things that wait for no one. Do you need 5G? No. Do you want it? Probably not. But it’s here, so be a good consumer and dump all your 4G hardware in the name of technical progress.

This line of logic may explain how the Verizon-branded Netgear AC791L 4G “Jetpack” hotspot you see here, despite being in perfect working order, found itself in the trash. The onset of 5G must have been particularly quick for the previous owner, since they didn’t even bother to wipe their configuration information from the device. In the name of journalistic integrity I won’t divulge the previous owner’s identity; but I will say that their endearing choice of WPA2 key, iluvphysics, makes for a nice fit with our publication.

A quick check of eBay shows these devices, and ones like it, are in ample supply. At the time of this writing, there were more than 1,500 auctions matching the search term “Verizon jetpack”, with most of them going for between $20 and $50 USD. We like cheap and easily obtainable gadgets that can be hacked, but is there anything inside one of these hotspots that we can actually use? Let’s find out.

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