Retrofits Done Right: Physical Controls For Heated Seats

November 24, 2025 by Matt Varian 37 Comments

We’ve all owned something where one tiny detail drives us nuts: a blinding power LED, buttons in the wrong order, or a beep that could wake the dead. This beautifully documented project fixes exactly that kind of annoyance, only this time it’s the climate-controlled seats in a 2020 Ram 1500.

[projectsinmotion] wasn’t satisfied with adjusting seat heating and ventilation only through the truck’s touchscreen. Instead, they added real physical buttons that feel just like factory equipment. The challenge? Modern vehicles control seats through the Body Control Module (BCM) over a mix of CAN and LIN buses. To pull this off, they used an ESP32-S3 board with both CAN and LIN transceivers that sits in the middle and translates button presses into the exact messages the BCM expects.

The ESP32 also listens to the CAN bus so the new physical buttons always match whatever setting was last chosen on the touchscreen, no mismatched states, no surprises. On the mechanical side, there are 3D-printed button bezels that snap into blank switch plates that come out looking completely stock, plus a tidy enclosure for the ESP32 board itself. Wiring is fully reversible: custom adapters plug straight into the factory harness. Every pinout, every connector, and every wire color is documented with WireVis diagrams we’ve covered before, making this an easily repeatable seat-hack should you have a similar vehicle. Big thanks to [Tim] for the tip! Be sure to check out some of our other car hacks turning a mass produced item into one of a kind.

Retrofitting Robots

October 22, 2022 by Elliot Williams 27 Comments

Al Williams wrote up a neat thought piece on why we are so fascinated with robots that come in the shape of people, rather than robots that come in the shape of whatever it is that they’re supposed to be doing. Al is partly convinced that sci-fi is partly responsible, and that it shapes people’s expectations of what robots look like.

What sparked the whole thought train was the ROAR (robot-on-a-rail) style robot arms that have been popping up, at least in the press, as robot fry cooks. As the name suggests, it’s a robot arm on a rail that moves back and forth across a frying surface and uses CV algorithms to sense and flip burgers. Yes, a burger-flipping robot arm. Al asks why they didn’t just design the flipper into the stovetop, like you would expect with any other assembly line.

In this particular case, I think it’s a matter of economics. The burger chains already have an environment that’s designed around human operators flipping the burgers. A robot arm on a rail is simply the cheapest way of automating the task that fits in with the current ergonomics. The robot arm works like a human arm because it has to work in an environment designed for the human arm.

Could you redesign a new automatic burger-flipping system to be more space efficient or more reliable? Probably. If you did, would you end up with a humanoid arm? Not necessarily. But this is about patching robotics into a non-robotic flow, and that means they’re going to have to play by our rules. I’m not going to deny the cool factor of having a robot arm flip burgers, but my guess is that it’s actually the path of least resistance.

It feels kind of strange to think of a sci-fi timeline where the human-looking robots come first, and eventually get replaced by purpose-built intelligent machines that look nothing like us as the environments get entire overhauls, but that may be the way it’s going to play out. Life doesn’t always imitate art.

Exploring An Aftermarket LED Headlight Retrofit Kit

September 23, 2021 by Tom Nardi 30 Comments

There’s plenty of debate about drop-in LED headlight bulbs, especially when they’re used with older reflector housings that were designed for halogen bulbs. Whether or not you personally feel the ultra-bright lights are a nuisance, or even dangerous, one thing we can all agree on is that they’re clearly the result of some impressive engineering.

Which is why we were fascinated to see the teardown [TechChick] did on a “Ultra 2 LED” retrofit from GTR Lighting. Apparently one of the diodes was failing, and as part of the warranty replacement process, she was informed she had to make it completely inoperable. Sounds like a teardown dream come true. If a manufacturer ever told us we needed to take something apart with extreme prejudice and provide photographic evidence that the deed was done, we’d be all too happy to oblige.

The driver itself ended up being completely filled with potting compound, so she doesn’t spend much time there. Some will no doubt be annoyed that [TechChick] didn’t break out the small pointy implements and dig all that compound out, but we all pretty much know what to expect when it comes to driving LEDs. The real interesting bit is the bulb itself.

As is common with these high-output automotive LEDs, the Ultra 2 is actively cooled with a small fan that’s actually enclosed within the heatsink. With the fan and the two-piece heatsink removed, she’s able to access the LED module itself. Here, two PCBs are sandwiched back to back with a hollow copper chamber that leads out of the rear of the module. When [TechChick] cut into the copper she said she heard a hiss, and assumed it was some kind of liquid cooling device. Specifically we think it’s a vapor chamber that’s being used to pull heat away from the diodes and into the heatsink at the rear of the module, which speaks to the advanced technology that makes these bulbs possible.

While laser headlights are arguably the future of automotive lighting, it’s going to be quite some time before they trickle down to those of us that don’t own supercars. Until then, when used responsibly, these LED retrofits can inject a bit of cutting-edge tech into your old beater without breaking the bank.

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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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Retrofitting USB-C To An IPod Nano

January 18, 2021 by Danie Conradie 29 Comments

Some hacks serve a critical need, while others are just for the challenge or fun of it. We suspect the latter was the real reason [David Buchanan] converted a first generation iPod Nano from its original 30 pin connector to USB-C.

[David] bought the iPod with a dead battery, so when he opened the iPod to get the old battery out, he noticed there was enough space to fit a USB-C connector. The original Apple 30 pin connector runs USB 2.0 through four of the pins, so [David] used the original USB cable and identified the appropriate pins and traces with a continuity tester. The connector was destructively removed with side cutters, ripping off all but one of the pads in the process. A hot air station might have made things easier, but we assume he did not have one on hand. The USB-C connector was scavenged from a cheap USC-C to USB Micro adaptor and mounted by soldering the housing directly to the PCB’s ground plane. The three remaining terminals were soldered to the traces with enamel wire.

With the new battery installed, [David] confirmed that both charging and data transfer worked. The IC that handles the button and scroll pad interfered slightly with the new connector, so he filed away some of the IC’s excess. Any open pads close to the new connector was covered with Kapton tape to avoid shorts. The large hole in the enclosure for the 30 pin connection was partly filled in with five-minute epoxy. The final assembled product looks almost factory produced and works as it’s supposed to, so we call this a win.

Retrofitting USB-C connectors in various electronic devices has become a popular hack over the past two years. We’ve seen it done on everything from Thinkpads to soldering irons. Continue reading “Retrofitting USB-C To An IPod Nano” →

How To Retrofit A Pick And Place Machine For OpenPnP, In Detail

June 24, 2020 by Donald Papp 10 Comments

[Erich Styger] owns a Charmhigh CHM-T36VA pick and place machine, which he describes as well-built and a great value of hardware for the money. However, the software end is less impressive, with a proprietary controller that is functional but not great. The good news is that it is possible to retrofit the machine to use the OpenPnP framework, which is open-source and offers more features. Even better, [Erich] has already done and documented all the hard parts!

The CHM-T36VA has two heads, vision system, and uses drag feeders.

The conversion requires upgrading a few hardware parts such as the cameras, replacing the controller’s firmware, then installing and configuring OpenPnP (which runs on an attached PC.)

[Erich] does not recommend this conversion for anyone who is not very familiar with electronics, or has any worries about voiding warranties. Barring that, he suspects the conversion could be done in about a day or two’s worth of focused work. It took him two weeks, including time spent fine-tuning the first production job. He says the bulk of the time was spent on configuration, but he has shared his configuration on GitHub in the hopes that it will save a lot of time for anyone using the same hardware.

After populating some 300 boards and placing over 7000 parts, he’s very happy with the results. The machine places between 600 and 700 parts per hour, so speed might not be amazing but it’s perfectly serviceable. [Erich] finds that while the machine runs a little slower than it did with the original controller, it also runs much smoother and quieter overall. In return he gets what he truly wanted: a pick and place machine whose operation and configuration is entirely open and accessible. You can see it in action in the video, embedded below.

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Retrofit Temperature Control To A Soldering Station

April 7, 2018 by Jenny List 1 Comment

We’ve probably all seen USB soldering irons advertised for very little money, and concluded that they might not necessarily be the most useful of tools. The cheapest of these lack any real temperature regulation. Enter [Paulo Bruckmann], who has attached a thermistor to his iron with Kapton tape, added an Arduino Uno clone with rotary encoder and Nokia LCD, and put the result in a 3D printed case for a tiny and low powered temperature controlled soldering station. The claimed cost is only $10, which seems credible given the low price of Arduino clones.

The software provides the expected PID control, with the advantage of very quick warm-up due to the tip’s tiny size. The power source is 9 V rather than a USB 5 V, so the combination gives an iron capable of working on much larger joints than when unmodified. He therefore seems to have created what appears to be a significantly more capable iron from this unpromising start, something we find quite impressive. Take a look at his video below the break.

We reviewed one of these little irons last year, and found it to be a toy, but not a joke. Meanwhile we’ve seen some other mods for them, including a pair of desoldering tweezers.

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