No Need For Inserts If You’re Prepared To Use Self-Tappers

September 2, 2025 by 57 Comments

As the art of 3D printing has refined itself over the years, a few accessories have emerged to take prints to the next level. One of them is the threaded insert, a a piece of machined brass designed to be heat-set into a printed hole in the part. They can be placed by hand with a soldering iron, or for the really cool kids, with a purpose-built press. They look great and they can certainly make assembly of a 3D printed structure very easy, but I’m here to tell you they are not as necessary as they might seem. There’s an alternative I have been using for years which does essentially the same job without the drama. Continue reading “No Need For Inserts If You’re Prepared To Use Self-Tappers” →

Checking Out A TV Pattern Generator From 1981

September 2, 2025 by 11 Comments

The picture on a TV set used to be the combined product of multiple analog systems, and since TVs had no internal diagnostics, the only way to know things were adjusted properly was to see for yourself. While many people were more or less satisfied if their TV picture was reasonably recognizable and clear, meaningful diagnostic work or calibration required specialized tools. [Thomas Scherrer] provides a close look at one such tool, the Philips PM 5519 GX Color TV Pattern Generator from 1981.

This Casio handheld TV even picked up the test pattern once the cable was disconnected, the pattern generator acting like a miniature TV station.

The Philips PM 5519 was a serious piece of professional equipment for its time, and [Thomas] walks through how the unit works and even opens it up for a peek inside, before hooking it up to both an oscilloscope and a TV in order to demonstrate the different functions.

Tools like this were important because they could provide known-good test patterns that were useful not just for troubleshooting and repair, but also for tasks like fine-tuning TV settings, or verifying the quality of broadcast signals. Because TVs were complex analog systems, these different test patterns would help troubleshoot and isolate problems by revealing what a TV did (and didn’t) have trouble reproducing.

As mentioned, televisions at the time had no self-diagnostics nor any means of producing test patterns of their own, so a way to produce known-good reference patterns was deeply important.

TV stations used to broadcast test patterns after the day’s programming was at an end, and some dedicated folks have even reproduced the hardware that generated these patterns from scratch.

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The Sense And Nonsense Of Virtual Power Plants

September 2, 2025 by 32 Comments

Over the past decades power grids have undergone a transformation towards smaller and more intermittent generators – primarily in the form of wind and solar generators – as well as smaller grid-connected batteries. This poses a significant problem when it comes to grid management, as this relies on careful management of supply and demand. Quite recently the term Virtual Power Plant (VPP) was coined to describe these aggregations of disparate resources into something that at least superficially can be treated more or less as a regular dispatchable power plant, capable of increasing and reducing output as required.

Although not actual singular power plants, by purportedly making a VPP act like one, the claim is that this provides the benefits of large plants such as gas-fired turbines at a fraction of a cost, and with significant more redundancy as the failure of a singular generator or battery is easily compensated for within the system.

The question is thus whether this premise truly holds up, or whether there are hidden costs that the marketing glosses over.

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Build Your Own Pip-Boy Styled Watch

September 2, 2025 by 6 Comments

[Arnov Sharma]’s latest PIP-WATCH version is an homage to Pip-Boys, the multi-function wrist-mounted personal computers of Fallout.

We like the magnetic clasp on the back end.

[Arnov] has created a really clean wearable design with great build instructions, so anyone who wants to make their own should have an easy time. Prefer to put your own spin on it, or feel inspired by the wrist-mounted enclosure? He’s thoughtfully provided the CAD files as well.

Inside the PIP-WATCH is a neat piece of hardware, the Lilygo T-Display-S3 Long. It’s an ESP32-based board with a wide, touch-enabled, color 180 x 640 display attached. That makes it a perfect fit for a project like this, at least in theory. In practice, [Arnov] found the documentation extremely lacking which made the hardware difficult to use, but he provides code and instructions so there’s no need to go through the same hassles he did.

In addition to the Hackaday.io project page, there’s an Instructables walkthrough.

If you put your own spin on a Pip-boy (whether just a project inspired by one, or a no-detail-spared build of dizzying detail) we want to hear about it, so be sure to drop us a tip!

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Remembering The Intel Compute Stick

September 2, 2025 by 29 Comments

Over the years Intel has introduced a number of new computer form factors that either became a hit, fizzled out, or moved on to live a more quiet life. The New Unit of Computing (NUC) decidedly became a hit with so-called Mini PCs now everywhere, while the Intel Compute Stick has been largely forgotten. In a recent video by the [Action Retro] one such Compute Stick is poked at, specifically the last model released by Intel in the form of the 2016-era STK1AW32SC, featuring a quad-core Intel Atom x5-Z8330 SoC, 2 GB of RAM and 32 GB eMMC storage.

As the name suggests, this form factor is very stick-like, with a design that makes it easy to just plug it into the HDMI port of a display, making it a snap to add a computer to any TV or such without taking up a considerable amount of space. Although Intel didn’t make more of them after this model, it could be argued that devices like the Chromecast dongle follow the same general concept, and manufacturers like MeLe are still making new PCs in this form factor today.

In the video this 2016-era Compute Stick is put through its paces, wiping the Windows 10 installation that was still on it from the last time it was used, and an installation of Haiku was attempted which unfortunately failed to see the eMMC storage. Worse was the current Ubuntu, which saw its installer simply freeze up, but MX Linux saved the day, providing a very usable Linux desktop experience including the watching of YouTube content and network streaming of Steam games.

Although dissed as ‘e-waste’ by many today, if anything this video shows that these little sticks are still very capable computers in 2025.

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Tiny Datasette Uses USB For The Modern Day

September 1, 2025 by 28 Comments

While you can still find tape being used for backup storage, it’s pretty safe to say that the humble audio cassette is about as out of date as a media format can be. Still, it has a certain retro charm we’re suckers for, particularly in the shape of a Commodore Datasette. We’re also suckers for miniaturization, so how could we not fall for [bitluni] ‘s tiny datasette replica?

Aesthetically, he’s copying the Commodore original to get those sweet nostalgia juices flowing, but to make things more interesting he’s not using compact cassette tapes. Instead, [bitluni] started with a micro cassette dictaphone, which he tore down to its essentials and rebuilt into the Commodore-shaped case.

The prototyping of this project was full of hacks — like building a resistor ladder DAC in an unpopulated part of a spare PCB from an unrelated project. The DAC is of course key to getting data onto the micro cassettes. After some playing around [bitluni] decided that encoding data with FSK (frequency-shift keying), as was done back on the C-64, was the way to go. (Almost like those old engineers knew what they were doing!) The dictaphone tape transport is inferior to the old Datasette, though, so as a cheap error-correction hack, [bitluni] needed to duplicate each byte to make sure it gets read correctly.

The micro cassettes only fit a laughable amount of data by modern standards this way (about 1 MB) but, of course that’s not the point. If you jump to 11:33 in the video embedded below, you can see the point: the shout of triumph when loading PacMan (all 8 kB of it) from tape via USB. That transfer was via serial console; eventually [bitluni] intends to turn this into the world’s least-practical mass storage device, but that wasn’t necessary for proof-of-concept. The code for what’s shown is available on GitHub.

If you have an old Datasette you want to use with a modern PC, you’d better believe that we’ve got you covered. We’ve seen other cassette-mass-storage interfaces over the years, too. It might be a dead medium, but there’s just something about “sticky tape and rust” that lives on in our imaginations.

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Old Projects? Memorialize Them Into Functional Art

September 1, 2025 by 3 Comments

What does one do with old circuit boards and projects? Throwing them out doesn’t feel right, but storage space is at a premium for most of us. [Gregory Charvat] suggests doing what he did: combining them all into a wall-mountable panel in order to memorialize them, creating a functional digital clock in the process. As a side benefit, it frees up storage space!

Everything contributes. If it had lights, they light up. If it had a motor, it moves.

Memorializing and honoring his old hardware is a journey that involved more than just gluing components to a panel and hanging it on the wall. [Gregory] went through his old projects one by one, doing repairs where necessary and modifying as required to ensure that each unit could power up, and did something once it did. Composition-wise, earlier projects (some from childhood) are mounted near the bottom. The higher up on the panel, the more recent the project.

As mentioned, the whole panel is more than just a collage of vintage hardware — it functions as a digital clock, complete with seven-segment LED displays and a sheet metal panel festooned with salvaged controls. Behind it all, an Arduino MEGA takes care of running the show.

Creating it was clearly a nostalgic journey for [Gregory], resulting in a piece that celebrates and showcases his hardware work into something functional that seems to have a life of its own. You can get a closer look in the video embedded below the page break.

This really seems like a rewarding way to memorialize one’s old projects, and maybe even help let go of unfinished ones.

And of course, we’re also a fan of the way it frees up space. After all, many of us do not thrive in clutter and our own [Gerrit Coetzee] has some guidance and advice on controlling it.

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