Cut Your Own Gears With This DIY Machine

January 27, 2023 by Zoe Skyforest 29 Comments

You can buy gears off the shelf, of course, and get accurately machined parts exactly to your chosen specification. However, there’s something rugged and individualist about producing your own rotating components. [Maciej Nowak] demonstrates just how to produce your own gears with a homemade cutting tool.

The cutting tool for the job is an M16 machine tap, chosen for the smaller flutes compared to a hand tap. This makes it more suitable for cutting gears. It’s turned by a belt driven pulley, run by a small motor. The workpiece to be cut into a gear is then fed into the cutting tool by sliding on a linear bearing, with its position controlled by a threaded rod. The rod can be slowly turned by hand to adjust the workpiece position, to allow the gear teeth to be cut to an appropriate depth.

The method of action is simple. As the tap turns it not only cuts into the workpiece, but rotates it on a bearing as well. By this method, it cuts regular teeth into the full circumference, creating a gear. Obviously, this method doesn’t create highly-complex tooth shapes for ultimate performance, but it’s more than capable of creating usable brass and steel gears for various purposes. The same tool can be used to cut many different sizes of gear to produce a whole geartrain. As a bonus, the resulting gears can be used with M16 threads serving as worm gears, thanks to the pitch of the tap.

If you find yourself needing to produce tough metal gears on the regular, you might find such a tool very useful. Alternatively, we’ve explored methods of producing your own sprockets too, both in a tidy manner, and in a more haphazard fashion. Video after the break.

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LED Air Vent Gauges Are A Tasteful Mod For The Mazda Miata

January 27, 2023 by Zoe Skyforest 23 Comments

Anyone in the JDM scene can tell you, round air vents are prime real estate for round analog gauges. If you want a gauge but don’t want to block your vent, you could consider building these LED vent gauges from [ktanner] instead.

The design is simple. It relies on 3D printing a replacement bezel for the Mazda Miata’s stock round air vents. This bezel is designed to hold a NeoPixel ring from Adafruit. When built with the optional laser-cut diffuser, the parts have a near-stock look when the LEDs are turned off. It’s a classy, stealthy mod – exactly the sort of thing Miata owners need but never seem to have! (Author Note: don’t be mad, I was once one of you!)

With 24 addressable RGB LEDs, it’s possible to display all kinds of data by turning the LEDs on and off and varying the colors. For example, you could readily build a boost gauge that turns on more LEDs at higher boost pressure. It could then be set up to flash red in the event that you surpass safe thresholds. [ktanner] hasn’t specified any particular microcontroller for the setup — but just about any part you like can be used to drive NeoPixels, after all.

If you’re new to NeoPixels, you might find a simulator useful for developing your projects. Meanwhile, if you’re doing similar work on other cars, be sure to hit us up on the tipsline!

3D Printer Spool Roller Is Built For Giant Spools Of Filament

January 27, 2023 by Zoe Skyforest 15 Comments

Most 3D printers come with a pretty basic filament holder — often little more than a bar to hang the spool on. [Ivan Miranda]’s 3D printers run bigger spools than most, though, so he had to craft an altogether more serious solution.

Unlike most of [Ivan]’s creations, the spool holder isn’t actually 3D printed. For this job, he turned to a laser cutter instead, cutting the parts out of 5 mm plywood. A handful of layers of wood bolt together to form the frame. The frame holds several bearings for the outer rims of the spool itself to ride on, allowing it to spin freely as the extruder tugs on the filament. Reducing the rolling resistance of the spool is key when working with such large, heavy spools, and reduces the chances of the filament not feeding properly.

It’s a tidy example of a tool built quickly and easily using a laser cutter. It pays to remember that while 3D printers are great, a laser cutter can often turn out parts in a short fraction of the time.

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Lego Guitar Is Really An Ultrasonically-Controlled Synth

January 26, 2023 by Zoe Skyforest 4 Comments

The phrase “Lego Guitar” can be a stressful one to hear. You might imagine the idea of strings under tension and a subsequently exploding cloud of plastic shrapnel. This build from the [Brick Experiment Channel] eschews all that, thankfully, and is instead a digital synth that only emulates a guitar in its rough form factor.

The heart of the build is a Lego Mindstorms EV3 controller. It’s acts as the “body” of the guitar, and is fitted with a Lego “fretboard” of sorts. A slide is moved up and down the fretboard by the player. The EV3 controller detects the position of the slide via an ultrasonic sensor, and uses this to determine the fret the user is trying to play. The button the user presses on the controller then determines which of five “strings” the user is playing, and the selected note is sounded out from the EV3’s internal speaker. It’s strictly a monophonic instrument, but three different sounds are available: a bass guitar, a rock guitar, and a solo guitar, with all the fidelity and timbre of a 90s Casio keyboard.

It’s a fun and silly instrument, and also kind of difficult to play. The slide mechanism doesn’t offer much feedback, nor are the EV3 buttons intended for dynamic musical performance. Regardless, the player belts out some basic tunes to demonstrate the concept. We doubt you’d ever be able to play Through The Fire and Flames on such a limited instrument, but [Brick Experiment Channel] used their editing skills to explore what that might sound like regardless.

We’ve seen some other great synth guitars before, too. Modern microcontrollers and electronics give makers all kinds of creative ways to build electronic instruments with unique and compelling interfaces. Some are more successful than others, but they’re all fun to explore. Video after the break.

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Binary Watch Rocks A Bare PCB With Pride

January 26, 2023 by Zoe Skyforest 18 Comments

Most of us learn to read digital clocks first, which display the time in obvious numbers. Analog clocks are often learned later, with the hands taking our young brains a little longer to figure out. Once you’ve grown into a 1337h4XX0r, though, you’re ready to learn how to read a binary watch. Then you can build your own, just like [taifur] did.

The watch rocks a simplistic, bare bones design with the PCB acting as the body of the device itself. It’s not great for water resistance, or even incidental contact, but it’s a sharp look with the golden traces on display. The heart of the operation is a ATmega328P, as seen in the popular Arduino Uno, and it’s paired with a DS3231M real-time clock module to keep accurate time. 13 SMD LEDs are charged with displaying the time in binary format, with [taifur] choosing to spec a classic red color for the build. The watch is powered via a CR2032 coin cell, which you’re best advised not to swallow. So far, [taifur] has found the watch will last for over a month before the battery is tapped out.

It’s a fun build, and one that looks good when paired with a classic NATO watch strap in green. If, however, you desire a watch that definitely won’t last a month on a single coin cell, you can always build a Nixie watch instead. Video after the break.

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A Simple Air Suspension Demo With Lego Technic

January 25, 2023 by Zoe Skyforest 19 Comments

The most common suspension systems on automobiles rely on simple metal springs. Leaf spring and coil spring designs both have their pros and cons, but fundamentally it’s all about flexing metal doing the work. Air suspension works altogether differently, employing gas as a spring, as demonstrated by this simple Lego build from [JBRIX].

The suspension system is employed on a Lego Technic car, with a relatively unsophisticated design. The car has no real form of propusion, and serves solely to demonstrate the air suspension design. They may look like dampers, but the system is actually using Lego pneumatic pistons as springs for each wheel. The pistons are connected to the upper control arm of a double wishbone suspension setup. Each piston is pneumatically connected to a main reservoir. With the reservoir, and thus the pistons, pressurized, the suspension system can support the weight of the car. If a bump perturbs a wheel, the piston compresses the air in the system, which then returns the piston to its original position, thus serving as a spring. If the reservoir is vented, the suspension collapses. Air springs on real, full-sized automobiles work in basically the same way. However, they usually have a separate reservoir per corner, keeping each wheel’s suspension independent.

Overall, if you’re working on some kind of Lego rambler, you might find this suspension concept useful. Alternatively, you might simply find it good as a learning aid. If you want to learn more about oddball suspension systems, we can help there too. Video after the break.

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Pizza-Making CNC Machine Is The Only Tool We’ve Ever Dreamed Of

January 25, 2023 by Zoe Skyforest 20 Comments

Making pizza is fun, but eating pizza is even better. Ideally, you’ll get to spend much more time doing the latter than the former. If you had a pizza-making CNC machine, that would help you achieve this goal, and thankfully, [Twarner] is working on that very technology.

The Pizza-Pizza CNC Machine is based on Marlin firmware running on a Mini RAMbo 3D printer motherboard, and is a 3-axis CNC machine. At a glance, you could be forgiven for thinking it’s some kind of fancy futuristic vinyl player, but it’s actually intended to cook a tasty delicious pie. It’s a gantry-based machine that uses two tool ends, one charged with distributing sauce, and the other cheese. It’s programmed with G-code to designate areas to coat with sauce and areas to cover with cheese. It can’t create dough from scratch sadly, but instead operates using pre-manufactured pizza bases.

The current level of sophistication is low, and there are issues with cheese clogs and the general messiness of the operation. However, this doesn’t mean there’s no value in automated pizza manufacture. If anything, we want to see the more open-sauce development in this area until we end up with a pizza factory on every kitchen bench worldwide. We’ve already seen that hackers have mastered how to build a good pizza oven, so now we just need to solve this part of the equation. Video after the break.

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