Hackaday Podcast 123: Radioactive Rhinos, Wile E. Coyote Jetpack, Radio Hacks 3-Ways, And Battery Welders On The Spot

Hackaday’s Mike Szczys is taking a bit of vacation this week, so Elliot is joined by Staff Writer Dan Maloney to talk about all the cool hacks and great articles that turned up this week. Things were busy, so there was plenty to choose from, but how would we not pick one that centers around strapping a jet engine to your back to rollerskate without all that pesky exercise? And what about a light bulb that plays Doom – with a little help, of course. We’ll check out decals you can make yourself and why the custom keyboard crowd might want to learn that skill, learn about the other “first computer”, and learn how a little radiation might be just what it takes to save an endangered species.

Take a look at the links below if you want to follow along, and as always, tell us what you think about this episode in the comments!

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Upgrading The PowerBook 100 With A Fresh New Battery

The PowerBook 100 was one of the earliest Apple laptops released, coming not long after the breakout Macintosh Portable. Unlike modern hardware, it relied on sealed lead acid batteries. [360alaska] has such a laptop whose original battery is long dead, so they set about building a replacement battery with lithium cells instead.

The battery and its associated support circuitry is a mite unconventional in its design, but it gets the job done. The build uses two lithium polymer pouch cells in place of the original four cell sealed-lead acid battery, to replicate the roughly 7.2V nominal voltage. Because of this, unfortunately the stock PowerBook charger can’t provide enough voltage to fully charge the LiPo cells up to their full 8.4 volts.

The workaround selected is that when the batteries fall below 80% state of charge, relays disconnect the cells from their series configuration powering the laptop, and instead connect each cell to its own single-cell charger board. Once charging is complete, the relays switch back out of charging mode so the batteries power the laptop once more. The only major drawback is that withdrawing the power adapter while the batteries are on charge will cut all power to the laptop.

It may not be perfect, but [360alaska] has succeeded in building a drop-in battery solution for the PowerBook 100 that can be used with the stock charger. Laptop batteries can be a fraught thing to deal with; often there are safeguards or DRM-type issues to navigate to get them to work around. Sometimes open-source designs are the best solution out there.

Review: Battery Spot Welders, Why You Should Buy A Proper Spot Welder

Making battery packs is a common pursuit in our community, involving spot-welding nickel strips to the terminals on individual cells. Many a pack has been made in this way, using reclaimed 18650 cells taken from discarded laptops. Commercial battery spot welders do a good job but have a huge inrush current and aren’t cheap, so it’s not uncommon to see improvised solutions such as rewound transformers taken out of microwave ovens. There’s another possibility though, in the form of cheap modules that promise the same results using a battery pack as a power supply.

With a love of putting the cheaper end of the global electronic marketplace through its paces for the entertainment of Hackaday readers I couldn’t resist, so I parted with £15 (about $20), for a “Mini Spot Welder”, and sat down to wait for the mailman to bring me the usual anonymous grey package.

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A Vacuum Battery Made For Looks And Learning

Looks and RGB LEDs are usually not a priority in tool batteries, but [Oleg Pevtsov] decided the battery for his DIY vacuum cleaner needed to be different. In the process, he learned some lessons in chemical etching, plating, machining, casting, and electronics. See the video after the break for the build compilation.

The core of the battery is just five 18650 cells in a 3D-printed holder with a BMS, but the real magic is in the external components. The outer body is a brass tube with the logo etched through the 0.6 mm wall. Getting the etching right took a few tries and a lot of frustration, but he eventually found success with a solution of sulfuric acid and nitric acid in a magnetically stirred container. For etch resist he sprayed lacquer on the outside and filled the inside with silicone. The inside was then coated with clear epoxy by allowing it to cure while spinning. The final touches were nickel plating, then gold plating, and a high polish.

The silver-plated connector on one end consists of a machined copper tip and ring, epoxied together for isolation. The tip has a multi-start external thread, allowing the female side of the connector to securely connect with a single twist. A set of RGB LEDs were added to the core to light up the battery from the inside. We have to hope the vacuum this is supposed to attach to is equally impressive.

This being Hackaday, we see a lot of custom power banks for all the custom electronics. These range from a small power bank for on-the-go soldering to a heavy metal beast with a built-in inverter.

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A Hot-Swappable Battery Grip Keeps The Camera Rolling

There’s nothing worse than being in the middle of an important shot, only to have the camera’s batteries die on you. The losses can be very real, so it’s best to avoid them entirely. In an effort to do so, [funkster] built himself a battery grip for his Canon EOS M.

The hack is based around the venerable 18650 battery, packing 3.6V of lithium-ion goodness into a compact metal can. [funkster]’s build has slots for two of these cells, powering the camera off of one and keeping the other in reserve. The cells are monitored by a STM32 microcontroller, which switches from one battery to another as they run out or are removed. This allows batteries to be swapped while the camera is on – a highly useful feature. There’s even an OLED display to keep an eye on the state of charge of each cell.

The manner in which power is connected to the camera is rather amusing. An original Canon battery that slides inside the camera was gutted and turned into a simple adapter for the battery port. The battery grip, which wraps around the camera body, connects to this via pin headers that pass through a hole drilled in the camera’s case. It’s a permanent mod, but one [funkster] is happy with for the added usability – especially as doing it this way still provides easy access to the SD card slot.

Keeping a camera juiced on the go can be a headache without the right gear. [funkster] demonstrates that if you can’t buy it, you can always build it yourself. If your problem isn’t battery power, but your camera is overheating, you can of course fix that too. Video after the break.

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BMW Pushing Hard For Solid-State Battery Tech; Plans Demo By 2025

Plenty of development is ongoing in the world of lithium batteries for use in electric vehicles. Automakers are scrapping for every little percentage gain to add a few miles of range over their competitors, with efforts to reduce charging times just as frantic as well.

Of course, the real win would be to succeed in bringing a bigger, game-changing battery to market. Solid state batteries fit the bill, potentially offering far greater performance than their traditional lithium counterparts. BMW think there’s merit in the technology, and have announced they intend to show off a solid-state battery vehicle by 2025.

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Battery Analyzer Puts Alkaline Cells To The Test

We know, we know. Generally speaking, you should try and switch your household devices over to rechargeable cells rather than using disposable alkaline batteries. But while they might seem increasingly quaint in the lithium-ion era, features such as a long shelf life make it worth keeping a pack of disposables around. So which ones should you buy? That’s what [Moragor] wanted to find out with his personal battery analyzer.

Designed as a shield for the Arduino Mega 2560, the analyzer combines a small programmable electronic load with a INA219 current sensor, OLED display, and SD card reader. The user selects the cutoff voltage and discharge rate before the test begins, and once it’s running, data is collected every second and saved to the SD card for later analysis. Once the battery voltage reaches the predetermined value, the test is over and you’re ready to put a new cell through its paces.

After testing 27 different brands of batteries, [Moragor] tabulated all the data and produced some helpful charts to illustrate the results. With few exceptions, the performance level for most of the batteries was remarkably similar. If anything, the test seemed to show that higher tier batteries from companies like Duracell and Energizer actually performed slightly worse than the mid-range offerings. Perhaps the biggest surprise is that, when the per-cell cost was factored in, the local cheapo batteries provided a better value than anything else in the test.

While the selection of battery brands may be different from where you live, the data [Moragor] collected is still a fascinating even if you don’t recognize some of the names on the chart. Of particular note is the confirmation that lithium batteries handily outperformed any of the Alkaline cells tested when it came to high-drain applications. We’d still rather they came in rechargeable form, but at least it’s a step in the right direction.