Retrofitting Fast Charging To A Nissan Leaf EV

June 28, 2021 by Zoe Skyforest 21 Comments

Electric cars have been around for a while now, and thus they’re starting to get chopped up and modded just like any other car. [Daniel Öster] is one such person doing the work, and recently posted his efforts to retrofit fast charging to an base-model Nissan Leaf that didn’t ship with the feature.

[Daniel] uses special high-voltage insulated tools when working on EVs for safety.

It’s an involved swap, requiring the substitution of several parts and surgery on the wiring loom. Cost of components was just 700 euros but the swap required 20 hours of labor. The vehicle in question is an early model Leaf that was already fitted with an upgraded 40 kWh battery, and the owner desired an upgrade to CHAdeMO fast charging to better use the larger pack.

The swap required the power distribution unit to be replaced, and the CHAdeMO port to be installed in the front of the car. The vehicle control module (VCM) also had to be opened in order to run a wire to a relay to activate the fast charging subsystem. Finally, wires had to be spliced to get everything to play nicely between the car and the fast charger.

[Daniel] had the benefit of quality forum resources and a Nissan Leaf that already had CHAdeMO to reference, which helped a lot. At the end of the day, the fast charger worked first time, much to [Daniel]’s relief. We’ve featured his work before, too. Video after the break.

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Turning A MIG Welder Into A Metal 3D Printer

June 27, 2021 by Zoe Skyforest 70 Comments

Metal 3D printers are, by and large, many times more expensive than their FDM and resin-based brethren. It’s a shame, because there’s plenty of projects that would benefit from being able to produce more heat-resistant metal parts with additive fabrication methods. [Integza]’s rocketry projects are one such example, so he decided to explore turning a MIG welder into a 3D printer for his own nefarious purposes. (Video, embedded below.)

The build is as simple as you could possibly imagine. A plastic adapter was printed to affix a MIG welding nozzle to an existing Elegoo Neptune 2 3D printer. Unfortunately, early attempts failed quickly as the heat from the welding nozzle melted the adapter. However, with a new design that held the nozzle handle far from the hot end, the ersatz metal 3D printer was able to run for much longer.

Useful parts weren’t on the cards, however, with [Integza] facing repeated issues with the steel bed warping from the heat of the welding process. While a thicker steel base plate would help, it’s likely that warping could still happen with enough heat input so more engineering may be needed. It’s not a new concept by any means, and results are typically rough, but it’s one we’d like to see developed further regardless.

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Coding A Custom Driver For The Adafruit Mini Thermal Printer

June 26, 2021 by Zoe Skyforest 6 Comments

Thermal printers are cool… or, uh, warm actually. They use heat to make images, so they never need ink and they print on receipt rolls. The thermal printer available from Adafruit is a particularly tasty example, as it comes fully documented for the budding hacker. [Ed] is one such person, who set about writing his own driver to use the hardware with Linux on a Raspberry Pi.

The project came about as [Ed] didn’t like the halftone output from the standard Adafruit CUPS driver. Thus, a dithering-capable driver was needed instead. The first step of the project was to get dithering working via running such an algorithm into a custom driver, as well as to vary the heating time of the print head to gain greyscale capability. From there, the driver was integrated with CUPS and could be used with the Linux lp command. Finally, measures to deal with the paper running out were coded in as well.

It’s a fun dive into the nitty-gritty of talking to printers at the low level, something that few of us think about when printing concert tickets in a rush. There’s a lot that goes on to get a page to print successfully, and [Ed]’s work leaves us more respect for everything that goes on to get an image on the paper. The driver is available for keen tinkerers over at Github.

Meanwhile, consider a thermal printer for all your banner-printing needs.

Casting A Simple 3D Print In Aluminium

June 25, 2021 by Zoe Skyforest 21 Comments

3D printing with plastics and resins is great for quickly prototyping parts with all manner of geometries, but strength and durability of the parts produced is often limited. One way around this is to use your 3D printed parts as patterns for casting in something tougher like aluminium. That’s precisely what [Brian Oltrogge] did to produce an attractive wall hook from a 3D printed design.

The process starts with the design and printing of a wall hook, with [Brian] taking care to include the proper draft angles to allow the pattern to be properly removed from the mold. The print is carefully sanded down and post-processed to be highly smooth, so that it doesn’t spoil the mold when its removed for the casting process. From there, a sand casting mold is built around the pattern using sodium silicate in a 3-4% mix by weight with fine masonry sand. Once ready, the pattern is removed, and the mold is assembled, ready for the pour.

[Brian] completes the process with a simple gravity casting method using molten aluminium. The part is then removed from the mold, and filed down to improve the surface finish from the sand casting process. It’s then polished up to a nice shine and hung on the wall.

[Brian] does a great job of explaining the basics of what it takes to get gravity casting right; draft angles in particular are something often ignored by beginners, yet are crucial to getting good results. You needn’t just settle for casting inanimate objects though; we’ve featured DIY casting processes for gears before, too. Video after the break.

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Game Boy Color Gets A Rechargeable Battery

June 25, 2021 by Zoe Skyforest 21 Comments

Nintendo’s classic Game Boy has long been the darling queen of the handheld scene. However, with many fans modifying their handhelds with power-sucking features like modern backlit LCDs, running on AA batteries can become a frustrating exercise as they rapidly run out. [esotericsean] gets around that by modifying his Game Boys with a USB rechargeable battery setup. (Video, embedded below.)

The hack is a simple one, but the execution is quite tidy. [esotericsean] starts by removing the original DC jack from the Game Boy motherboard, and hogs out the hole in the case to fit a micro USB port. The original battery housing is similarly carved out to suit a 2000 mAh lithium-polymer pouch cell. A single-cell charging board is used to manage the battery, with its original connector removed and replaced with a neater-looking panel mount micro USB port instead. The electronics is then wrapped up in Kapton tape and stuffed inside the shell as everything is put back together.

The result is a USB rechargeable Game Boy that lasts for ages. [esotericsean] reports playing the console for hours each day for a full week without running out of power. The hack could become popular with chiptuners who often knock AA cells out of their handhelds during the more enthusiastic parts of their sets. We’ve seen similar hacks for other Game Boy models, too. Continue reading “Game Boy Color Gets A Rechargeable Battery” →

Simulating The Game Boy Printer’s Actual Paper Output

June 25, 2021 by Zoe Skyforest 7 Comments

Sometimes, we appreciate electronic devices not for their outright performance and crystal clear output, but precisely because they kind of suck in a unique and charming way. The Game Boy Camera, and its companion the Game Boy Printer, are much loved for precisely this reason. [Raphael BOICHOT] decided that he wanted to simulate the analog reality of the latter printer’s output in code, and set about the hefty coding task.

The result is the Game Boy Printer Paper Simulation, and it does a great job of reproducing the grainy, somewhat noisy output of the original thermal printer. The simulation was coded with the assistance of multiple high-resolution scans of the original printer’s output, which allowed [Raphael] to create a mathematical model of how the original digital pixelized image came out when hot thermal print head was put to paper.

What started with a single dot became a fully-fledged simulation package that can be run in MATLAB and Octave. It allows the end user to generate legitimate-looking images of Game Boy Printer output without actually having to own the printer and a roll of thermal paper.

We’ve seen Nintendo’s much-beloved printer before, such as this hack that turns it into an 8-bit photo gun. If you’re meddling with thermal printers yourself, be sure to let us know!

Turning GameCube & N64 Pads Into MIDI Controllers

June 19, 2021 by Zoe Skyforest 2 Comments

It’s fair to say that the Nintendo 64 and GameCube both had the most unique controllers of their respective console generations. The latter’s gamepads are still in high demand today as the Smash Bros. community continues to favor its traditional control scheme. However, both controllers can easily be repurposed for musical means, thanks to work by [po8aster].

The project comes in two forms – the GC MIDI Controller and the N64 MIDI Controller, respectively. Each uses an Arduino Pro Micro to run the show, a logic level converter, and [NicoHood’s] Nintendo library to communicate with the controllers. From there, controller inputs are mapped to MIDI signals, and pumped out over traditional or USB MIDI.

Both versions come complete with a synth mode and drum mode, in order to allow the user to effectively play melodies or percussion. There’s also a special mapping for playing drums using the Donkey Konga Bongo controller with the GameCube version. For those eager to buy a working unit rather than building their own, they’re available for purchase on [po8aster’s] website.

It’s a fun repurposing of video game hardware to musical ends, and we’re sure there’s a few chiptune bands out there that would love to perform with such a setup. We’ve seen other great MIDI hacks on Nintendo hardware before, from the circuit-bent SNES visualizer to the MIDI synthesizer Game Boy Advance. Video after the break.

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