Peeking Inside A VW Gearbox Reveals Die Casting Truths

December 14, 2020 by Zoe Skyforest 70 Comments

Recently, I was offered a 1997 Volkswagen Golf for the low, low price of free — assuming I could haul it away, as it suffered from a thoroughly borked automatic transmission. Being incapable of saying no to such an opportunity, I set about trailering the poor convertible home and immediately tore into the mechanicals to see what was wrong.

Alas, I have thus far failed to resurrect the beast from Wolfsburg, but while I was wrist deep in transmission fluid, I spotted something that caught my eye. Come along for a look at the nitty-gritty of transmission manufacturing!

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Building A Tiny Finger Plane For Detailed Work

December 14, 2020 by Zoe Skyforest 16 Comments

A plane is a tool familiar to all woodworkers, used to shape a workpiece by hand by shaving away material. Regular planes are two-handed tools available at all good hardware stores. For finer work, a finger plane can be useful, though harder to find. Thankfully, [Daniel] put together a video showing how to make your own.

[Daniel]’s build relies on stabilized wood, useful for its density and consistent quality, though other woods work too. A 6″ pen blank is enough to make a pair of matching finger planes. A block and two side panels are cut out from the material, with attention paid to making sure everything remains square for easy assembly. The parts are glued together with a block set at the desired cutting angle for the plane. With the assembly then tidied up on the bandsaw and sander, [Daniel] installs the cutting blade. This can be made from a larger standard plane blade, or a cutdown chisel can be pressed into service. The blade is held in place with a wooden wedge beneath a metal pin. The pin itself is crafted from an old drill bit, cut down to size.

It’s a useful tool for doing fine plane work, for which a full-size tool would be ungainly. We can imagine it proving particularly useful in producing accurate scale models in smaller sizes. If you’re big into woodworking, consider giving your tools a good sharpen on the cheap, too. Video after the break.

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Homebuilt Racing Sim Does Almost Everything From Scratch

December 12, 2020 by Zoe Skyforest 16 Comments

If you desire a sim gaming rig, there are off-the-shelf options up and down the market that stretch as high as your budget can afford. Some choose to eschew this route, however and build their own from scratch. Few people go quite so far as [Popicasa POPStuDio], however.

The first version of the rig is about as hacked as you can possibly get, and it’s a joy to see it built from scrap. The wheel itself and the pedals are all built out of old PVC pipe, with a bunch of old wood screwed together for the frame. A cheap USB gamepad serves to handle input to the PC for the pedals and H-shifter. The H-shifter uses simple power switches, repurposed in an ingenious way to sense gear position. The knob itself is cast out of what appears to be hot glue. Steering is done by connecting the wheel to a flexible shaft that tips a smartphone back and forth, using its internal accelerometers and gyros to sense rotation. It’s not clear how this is tied into the PC running Project CARS, but it’s impressive nonetheless.

Version 2 of the build takes things up a notch, using an Arduino Leonardo to handle steering and pedal functions as a Human Interface Device. There’s also force feedback, via a hefty motor attached to the steering shaft via a belt drive. This version implements an H-shifter as well as paddle shifters too for a more modern experience.

Both builds are unique in the modern era for eschewing CNC or 3D printed parts. It’s all done by hand, taking days of effort, and using only basic tools. It’s refreshing to see such a complex build done with nothing but simple materials and sheer commitment. We’re sure [Popicasa POPStuDio] enjoys the rig, and we can’t wait to see where it goes next. Perhaps the next iteration will even feature a motion platform, perhaps built out of old forklift parts? Only time will tell. Video after the break.

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A Relay-Based Pseudorandom Number Generator

December 9, 2020 by Zoe Skyforest 10 Comments

There are a great variety of ways to build a random number generator, and similarly many ways to generate numbers that appear random, but in a pure mathematical sense generally aren’t. [Daniel Valuch] built a Christmas decoration that does the latter, displaying the results on an attractive flashing ornament.

The build relies on a 16-bit linear feedback shift register, or LFSR. The LFSR generates a stream of numbers, with each number dependent on the previous state of the register. Thus, the numbers generated are pseudorandom, not truly random, and depend on the initial seed value of the system. [Daniel] built the shift register using relays, which create a lovely clacking sound as the register operates, and LEDs, which glow depending on the values in the register.

The result is a cute Christmas ornament that blinks in a deterministic fashion, and has a great old-school look due to the exposed copper of the PCB and the retro LED colors used. The project also serves as a great way to learn about shift registers and basic relay logic, though the latter is rarely used these days for serious purposes. We’ve covered the topic before, too. Video after the break.

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Hyperloop: Fast, But At What Cost?

December 9, 2020 by Zoe Skyforest 162 Comments

When it comes to travelling long distances, Americans tend to rely on planes, while the Chinese and Europeans love their high speed rail. However, a new technology promises greater speed with lower fares, with fancy pods travelling in large tubes held at near-vacuum pressures. It goes by the name of Hyperloop.

Virgin Hyperloop recently ran the first-ever passenger test of a Hyperloop vehicle, reaching 100 mph on a short test track.

Spawned from an “alpha paper” put together by Elon Musk in 2013, the technology is similar to other vactrain systems proposed in the past. Claiming potential top speeds of up to 760 mph, Hyperloop has been touted as a new high-speed solution for inter city travel, beating planes and high speed rail for travel time. Various groups have sprung up around the world to propose potential routes and develop the technology. Virgin Hyperloop are one of the companies at the forefront, being the first to run a pod on their test track with live human passengers, reaching speeds of 100 mph over a short 500 meter run.

It’s an exciting technology with a futuristic bent, but to hit the big time, it needs to beat out all comers on price and practicality. Let’s take a look at how it breaks down.

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Home-Crafting A Motorcycle Throttle Hold

December 8, 2020 by Zoe Skyforest 38 Comments

Cruise control is a common feature on automobiles, though less so in the motorcycle market. Given that continual throttle application on long rides can be a real pain in the wrist, many riders long for such a convenience. As a cheat solution, bolt-on locks that hold the throttle at a set position are available, though quality varies and generally they need to be activated by the throttle hand anyway. [Nixie] wanted a solution that would leave the right hand entirely free, and held, rather than locked, the throttle.

The device [Nixie] came up with is essentially a brake that fits inside the throttle handle and holds it in position. This is achieved with a mechanism that presses a pair of small brake shoes into the inside of the throttle, holding it from rotating back to neutral when the rider lets go. The brake is activated by a control on the left handlebar via a Bowden cable, allowing [Nixie] to activate the throttle hold on the highway and use the right hand to check pockets or simply rest.

It’s a tidy build, and [Nixie] does a great job of explaining the various design choices and the intricacies of the Bowden cable actuated mechanism. It’s anything but a one-size-fits-all build, but other enterprising machinists could certainly duplicate the design for other motorcycles without too many problems.

For those interested in more traditional cruise control, we’ve featured a teardown of a simplistic 90s Jeep system before. Video after the break.

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Norway Leads The Charge To Phase Out Internal Combustion; China And The UK To Follow

December 7, 2020 by Zoe Skyforest 194 Comments

Climate change promises to cause untold damage across the world if greenhouse gas emissions continue at current levels for much longer. Despite the wealth of evidence indicating impending doom, governments have done what humans do best, and procrastinated on solving the issue.

However, legislatures around the world are beginning to snap into action. With transportation being a major contributor to greenhouse gas emissions — 16% of the global total in 2016 — measures are being taken to reduce this figure. With electric cars now a viable reality, many governments are planning to ban the sale of internal combustion vehicles in the coming decades.

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