Cut Your Own Gears With This DIY Machine

January 27, 2023 by Lewin Day 29 Comments

You can buy gears off the shelf, of course, and get accurately machined parts exactly to your chosen specification. However, there’s something rugged and individualist about producing your own rotating components. [Maciej Nowak] demonstrates just how to produce your own gears with a homemade cutting tool.

The cutting tool for the job is an M16 machine tap, chosen for the smaller flutes compared to a hand tap. This makes it more suitable for cutting gears. It’s turned by a belt driven pulley, run by a small motor. The workpiece to be cut into a gear is then fed into the cutting tool by sliding on a linear bearing, with its position controlled by a threaded rod. The rod can be slowly turned by hand to adjust the workpiece position, to allow the gear teeth to be cut to an appropriate depth.

The method of action is simple. As the tap turns it not only cuts into the workpiece, but rotates it on a bearing as well. By this method, it cuts regular teeth into the full circumference, creating a gear. Obviously, this method doesn’t create highly-complex tooth shapes for ultimate performance, but it’s more than capable of creating usable brass and steel gears for various purposes. The same tool can be used to cut many different sizes of gear to produce a whole geartrain. As a bonus, the resulting gears can be used with M16 threads serving as worm gears, thanks to the pitch of the tap.

If you find yourself needing to produce tough metal gears on the regular, you might find such a tool very useful. Alternatively, we’ve explored methods of producing your own sprockets too, both in a tidy manner, and in a more haphazard fashion. Video after the break.

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LED Air Vent Gauges Are A Tasteful Mod For The Mazda Miata

January 27, 2023 by Lewin Day 23 Comments

Anyone in the JDM scene can tell you, round air vents are prime real estate for round analog gauges. If you want a gauge but don’t want to block your vent, you could consider building these LED vent gauges from [ktanner] instead.

The design is simple. It relies on 3D printing a replacement bezel for the Mazda Miata’s stock round air vents. This bezel is designed to hold a NeoPixel ring from Adafruit. When built with the optional laser-cut diffuser, the parts have a near-stock look when the LEDs are turned off. It’s a classy, stealthy mod – exactly the sort of thing Miata owners need but never seem to have! (Author Note: don’t be mad, I was once one of you!)

With 24 addressable RGB LEDs, it’s possible to display all kinds of data by turning the LEDs on and off and varying the colors. For example, you could readily build a boost gauge that turns on more LEDs at higher boost pressure. It could then be set up to flash red in the event that you surpass safe thresholds. [ktanner] hasn’t specified any particular microcontroller for the setup — but just about any part you like can be used to drive NeoPixels, after all.

If you’re new to NeoPixels, you might find a simulator useful for developing your projects. Meanwhile, if you’re doing similar work on other cars, be sure to hit us up on the tipsline!

Hackaday Podcast 203: Flashlight Fuel Fails, Weird DMA Machines, And A 3D Printed Prosthetic Hand Flex

January 27, 2023 by Tom Nardi 2 Comments

This week, Editor-in-Chief Elliot Williams and Managing Editor Tom Nardi meet up virtually to talk about all the hacks that are fit to print. This week’s episode starts off with a discussion about the recently unveiled 2023 Hackaday.io Low-Power Challenge, and how hackers more often than not thrive when forced to work within these sort of narrow parameters. Discussion then continues to adding a virtual core to the RP2040, crowd-sourced device reliability information, and mechanical Soviet space computers. We’ll wrap things up by wondering what could have been had Mattel’s ill-fated ThingMaker 3D printer actually hit the market, and then engage in some wild speculation about the issues plaguing NASA’s latest Moon mission.

Check out the links below if you want to follow along, and as always, tell us what you think about this episode in the comments!

Available in the cloud, or as download!

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ESP8266 Coaster Keeps Your Drink Warm

January 27, 2023 by Abe Connelly 5 Comments

Looking for the perfect winter desk accessory? [Wq] has created a beautiful coaster made out of PCBs that can keep your drink warm with an internal heater. (Chinese).

An ESP8266 sits as the main controller, with an additional MQTT control option, where the whole unit is powered over a USB-C connection. On board PCB traces, in the shape of a Hilbert curve, create the heating element used to heat beverages placed on the coaster, where [Wq] reports a measured resistance of the PCB trace network at 1.2 ohms. [Wq] writes that an AON6324 MOSFET replaces the D4184 that was previously being used, but might need some testing to get working properly. There are two capacitive touch sensors which has a TTP223E capacitive touch controller attached to detect input, with a multi-colored FM-3528 RGB LED for user feedback.

We love the artistry that went into building the coaster. For adventurous hackers wanting to build their own, the bill of materials (BOM), source code and board files are all available. We’ve seen everything from coasters and to PCB reflow boards, so it’s nice to see experimentation with a combination of these ideas.

This Week In Security: GTA, Apple And Android, And Insecure Boot

January 27, 2023 by Jonathan Bennett 11 Comments

When we first saw tweets about a security issue in Grand Theft Auto V, it sounded a bit like a troll. “Press ‘alt and f4’ to unlock a cheat mode”, or the hacker that claims to be able to delete your character. [Tez2]’s warning tweet that you shouldn’t play GTA Online without a firewall sounds like another of these online urban legends. But this one actually seems legit. NIST is even in on the fun, assigning CVE-2023-24059 for the exploit.

When playing an online game, other users send a “join request” to join the active session. This packets can contain malformed data which has been observed to crash the game client remotely. It’s believed, though not publicly confirmed, that it’s also a Remote Code Execution (RCE) vulnerability. It seems likely that this aspect will be added to some of the various cheat panels that are already widely used for this 10-year-old game. So now, rather than just giving your own character infinite ammo and health, you can inflict some havoc on other players, possibly up to corrupting their character files and getting them banned.

But why stop there? If we have code execution inside the game, what stops another player from launching a real attack? A video game isn’t sandboxed like a browser, and there’s nothing preventing a disk wiper attack or even a worm from compromising a bunch of players. The worst part is that it’s an old game, and even though there’s a large playerbase, it’s not guaranteed to get a fix. There’s at least one project aiming to be a firewall to prevent the issue. Continue reading “This Week In Security: GTA, Apple And Android, And Insecure Boot” →

Wolfenstein 3D, As You Never Imagined It.

January 27, 2023 by Jenny List 21 Comments

When tracing the history of first-person shooting (FPS) games, where do you credit with the genesis of the genre? Anyone who played 3D Monster Maze on the Sinclair ZX81 might dare to raise a hand, but we’re guessing that most of you will return to the early 1990s, and id Software. Their 1992 title Wolfenstein 3D might not have been the first to combine all the elements, but it’s arguably the first modern FPS and the first to gain huge popularity. Back in 1992 it needed at least a VGA card and a 286 to run, but here in 2023 [jhhoward] has taken it back a step further. You can now slay virtual Nazis in 3D on an 8088 PC equipped with a lowly CGA card.

Whether the gameplay survives in the sometimes-bizarre CGA color schemes and whether it becomes too pedestrian on an 8088 remains as an exercise for the reader to discover, but it’s a feat nevertheless. The textures all need converting to CGA mode before they can be used and there are even versions for the shareware and paid-for versions of the game. It’s possible that an 8088 may never be able to say yes to “Will it run DOOM?”, but at least now it can run the predecessor.

3D Printer Spool Roller Is Built For Giant Spools Of Filament

January 27, 2023 by Lewin Day 15 Comments

Most 3D printers come with a pretty basic filament holder — often little more than a bar to hang the spool on. [Ivan Miranda]’s 3D printers run bigger spools than most, though, so he had to craft an altogether more serious solution.

Unlike most of [Ivan]’s creations, the spool holder isn’t actually 3D printed. For this job, he turned to a laser cutter instead, cutting the parts out of 5 mm plywood. A handful of layers of wood bolt together to form the frame. The frame holds several bearings for the outer rims of the spool itself to ride on, allowing it to spin freely as the extruder tugs on the filament. Reducing the rolling resistance of the spool is key when working with such large, heavy spools, and reduces the chances of the filament not feeding properly.

It’s a tidy example of a tool built quickly and easily using a laser cutter. It pays to remember that while 3D printers are great, a laser cutter can often turn out parts in a short fraction of the time.

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