A mechanism made of brass and steel is attached to a milling machine. It has a long lever extending from the right side, a counterweight attached to the left side, and an indicator gauge in the middle.

A Precision Drill Press For Tiny Bits

May 16, 2026 by No comments

Anyone who’s worked with even a 1 mm bit knows that while a drill press is all but essential, it isn’t proof against broken bits. Working with a 0.1 mm drill bit seems, therefore, all but impossible, which is why [Mike] of Chronova Engineering built this mechanism to simplify such drilling.

The mechanism is an attachment for a milling machine, and in principle it just needs to move the rotating drill bit up and down. It needs to be extremely precise, though. For context, a good-quality chuck normally has a runout of 30 to 50 microns, which is approaching half the diameter of the drill bit. The mechanism has a collet mounted in the milling machine’s spindle, which transfers rotation to a second spindle. The second spindle is mounted to a runout-compensating drill chuck, and is connected to a lever and counterweight which allow the user to make small, low-force movements. A dial indicator lets the user see how far the bit’s descended.

Most of the parts were machined out of steel or brass, with the handle being made of titanium for lower weight. When the finished device was mounted to the milling machine, the measured runout was severe. After much investigation and reworking, however, the problem turned out to be a damaged collet locating pin, not an issue with the drilling mechanism. As a first test, [Mike] drilled a 0.1 mm hole 1.8 mm deep, then as a challenge drilled six 0.1 mm holes in the end of a thin steel wire. The results weren’t quite as uniform as he wanted, but it took a scanning electron microscope to even see the imperfection.

It won’t help much with very fine drill bits, but if you need a very precisely-placed hole, check out this periscopic drilling camera. If you do break a drill bit in the workpiece, you might be able to dissolve it with alum.

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Restoring A 3DO Blaster Card From The Early 90s

May 15, 2026 by 2 Comments

Before the modern trifecta of video game giants came to dominate the market around two decades ago, the world was awash in video game consoles. Many of these retro platforms have largely been forgotten outside of the enthusiast communities, and an average gamer today might not have ever heard of brands like ColecoVision or TurboGrafx. Among these unusual, rare, or forgotten systems was the 3DO which wasn’t strictly a console but rather a specification that manufacturers could use to make consoles on their own. But even more unusual was that this standard could be used to build 3DO-compatible expansion cards for PCs as well.

In this video, [The Retro Collective] received one of these boards to add to their museum, but like much retro hardware of this era it wasn’t working exactly like it would have out-of-the-box. After adding it to one of their period-correct 386 machines of the time, they found that it would only work properly with weight applied at one of the corners. This led to the discovery of some disconnected pins on the PCB, and a repair of that and some other issues brought the card back to life again.

The video also discusses the platform itself and shows how it would connect to a PC from that time. The PC would have needed a Sound Blaster card, a CD ROM drive with a particular proprietary interface, and a few other hardware requirements, but with everything up and working the player would have a console that theoretically competed with the original Playstation or Nintendo 64. It also illustrates an alternative path video games might have taken where expansion cards added console compatibility to any modern PC, but unfortunately the 3DO never really caught on.

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Inside The Heathkit Factory

May 15, 2026 by 4 Comments

If you are a certain age, you doubtlessly remember Heathkit. They produced a wide array of electronic kits that were models of completeness and clear instructions. They started with surplus war parts in 1947 and wound up a major player in ham radio and early personal computers. But they made so many other things like TVs, radio control planes, and test equipment. All of it was made for you to build yourself. [Unseen History] released a video with the story of Heathkit from the start to the finish.

The company started out building kit airplanes, but after the war, they built a kit for an oscilloscope using military surplus. The less than $40 scope was still pricey in 1947 when a pound of bacon sold for 64 cents. But a “real” oscilloscope at the time would cost at least $400. The rest is history.

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Adding Capabilities To Inexpensive Solar Modules

May 15, 2026 by 4 Comments

Solar power has gotten cheap enough that putting up panels is among the cheapest ways of providing energy. This isn’t just the case for bulk electricity on a power grid, either; even small devices are easier and cheaper to power with solar than ever before. For example, landscape lighting which once relied on 12V or 24V DC wires all over one’s yard with a transformer and power supply hidden somewhere have partially been converted to simpler individual solar-powered lights now. These small devices can also be given additional capabilities as [Mauro] demonstrates.

In this case, [Mauro]’s goal was to add on-demand lighting to a solar-powered light which was otherwise motion-activated only. To do this, they added a NRF24L01+ radio inside the light’s housing paired with an STM32 microcontroller. This secondary system is largely separated from the existing control circuitry with the exception of being able to switch the lights and receiving its power from the same solar panel. [Mauro] also created a small library to help with communicating with these new modules, whether that’s using a home automation system like Home Assistant or some other method.

Although adding in a few capabilities to inexpensive solar lighting might seem simple on the surface, a project like this is a gateway to adding in all kinds of interesting features to things with built-in solar panels and lots of free space in their cases. The best example here is the addition of a Meshtastic node to one of these lights, making it convenient and stealthy, but we could also see adding in other remote hardware to a landscape lighting module like a gate sensor or a plant health monitoring system.

Building A Die Filer From Scratch

May 15, 2026 by 4 Comments

A die filer is a useful tool to have if you find yourself filing parts on the regular. It’s basically a machine that reciprocates a file up and down for you so you can focus on filing the part to your desired dimensions. They’re not commonly manufactured these days, so [Richard Huberjohn] set about building his own. 

This die filer relies on a simple mechanism to turn rotational motion from a motor into reciprocating linear motion in the vertical plane. A rotating shaft is connected to a crank, which turns a pin in a slotted carrier attached to a linear bearing. As the wheel turns, the pin slides in the carrier, driving it and the linear rod up and down in turn. Attach a file to this, and you have a working die filer. In this case, the rotating shaft is driven by a pair of DC brushed motors, with output stepped down via a gearbox and then a short belt drive. Speed is varied with the aid of an off-the-shelf controller.

If you’re regularly filing small parts, a build like this could speed your work to a great degree. We’ve featured other DIY machine tool builds before, too. If you’re cooking up your own gear for the home workshop, don’t hesitate to let us know on the tipsline!

Mod This IKEA Lamp Into Smart Lighting For Not A Lot

May 15, 2026 by 4 Comments

The IKEA SKAFTSÄRV is an economical LED accent lamp, but while highly affordable it has only fixed lighting options. [simoneluconi] shows how it can easily be turned into a fully-configurable, WLED-connected, WiFi-enabled RGB lamp with little more than an ESP32-based board.

A thirty-LED lamp with integrated diffusor and stand can be had for surprisingly cheap. Add an equally-economical ESP32 board and it becomes a whole lot more.

To do this, the control board of the lamp gets replaced with an ESP32-C3 Super Mini board. Control and automation comes from WLED, open-source software that offers flexible automation and control for LED lights with a wide range of features, including native Android and iOS apps.

Modifying the SKAFTSÄRV lamp is fairly straightforward, but opening the unit does require breaking some glued seams to get inside. Once that’s done, the replacement board fits nicely into the housing and the unit can be closed back up. As far as WLED is concerned, the new lamp has 30 LEDs, WS281x type, GRB color order.

The end result is a stylish accent lamp with built-in diffusor and mount that can be controlled over WiFi with all the features WLED brings, such as easy integration with Home Assistant.

This isn’t the first time IKEA’s LED lighting has been given a powerup. Their pixel-style LED wall-mounted OBEGRÄNSAD, which displays a few canned animations out of the box, got considerably enhanced with a new controller.

Thanks [Crash] for the tip!

Hacking Hard Drive Firmware

May 15, 2026 by 15 Comments

You probably flash new firmware on a variety of devices regularly, even though that’s rare for non-technical types. But what about your hard drive firmware? Most of us don’t want to touch our operating drives, so unless you are dealing with surplus drives or have a special project in mind, you may not think much about the firmware running your spinning rust storage. [I Code 4 Coffee] uses hard drives in an unusual way to exploit Xbox 360s, and wound up reverse engineering some drive firmware with an eye to making changes.

The analysis started with three hard drives and an SSD. Looking for people who’ve done similar work wasn’t as productive as you might think. There isn’t much call for modifying hard drive firmware, and what data there is can be outdated.

One thing that was available was firmware dumps taken with a PC-3000 data recovery tool. What follows is a deep dive down the hard drive rabbit hole. There are backdoor vendor commands and connections to the diagnostic RS-232 port on some drives. You can find the technical artifacts on GitHub.

We learned a few things, and we bet you will too. Another way to get into the hard drive’s firmware is via JTAG.