Turning A Waterjet Cutter Into A Wood Lathe, For No Reason

On the shortlist of dream tools for most metalworkers is a waterjet cutter, a CNC tool that uses insanely high-pressure water mixed with abrasive grit to blast sheet metal into intricate shapes. On exactly nobody’s list is this attachment that turns a waterjet cutter into a lathe, and with good reason, as we’ll see.

This one comes to us by way of the Waterjet Channel, because of course there’s a channel dedicated to waterjet cutting. The idea is a riff on fixtures that allow a waterjet cutter (or a plasma cutter) to be used on tubes and other round stock. This fixture was thrown together from scrap and uses an electric drill to rotate a wood blank between centers on the bed of the waterjet, with the goal of carving a baseball bat by rotating the blank while the waterjet carves out the profile.

The first attempt, using an entirely inappropriate but easily cut blank of cedar, wasn’t great. The force of the water hitting the wood was enough to stall the drill; the remedy was to hog out as much material as possible from the blank before spinning up for the finish cut. That worked well enough to commit to an ash bat blank, which was much harder to cut but still worked well enough to make a decent bat.

Of course it makes zero sense to use a machine tool costing multiple hundreds of thousands of dollars to machine baseball bats, but it was a fun exercise. And it only shows how far we’ve come with lathes since the 18th-century frontier’s foot-powered version of the Queen of the Machine Shop.

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The Simplest TS100 Upgrade Leads Down A Cable Testing Rabbit Hole

By now, I must have had my Miniware TS100 soldering iron for nearly three years. It redefined what could be expected from the decent end of the budget soldering iron spectrum when it came on the market, and it’s still the one to beat even after those years. Small, lightweight, powerful, and hackable, it has even spawned direct imitations.

If the TS100 has a fault, it comes not from the iron itself but from its cable. A high-grade iron will have an extra-flexible PVC or silicone cable, but the TS100 does not have a cable of its own. Instead it relies on whatever cable comes on its power supply, which is frequently a laptop unit built with portable computing rather than soldering in mind. So to use it is to be constantly battling against its noticable lack of flexibility, a minor worry but one that I find irksome. I determined to find a solution, making a DC extension cable more flexible than that on my power supply. Continue reading “The Simplest TS100 Upgrade Leads Down A Cable Testing Rabbit Hole”

Open Source Stream Deck Does It Without Touch Screens

[Adam Welch] has built macro pads in the past out of pre-fab key matrices and handfuls of Cherry MX clones. But all the stickers and custom keycaps in the world wouldn’t make those macro pads as versatile as a stream deck — those visual shortcut panels with tiny touchscreens for each button that some streamers use to change A/V settings or switch between applications.

Let’s face it, stream decks are expensive. But 0.96″ OLED displays are not, and neither are SMD tactile buttons. Why not imitate a screen deck on the cheap by making it so the screens actuate buttons behind them? [Adam] based this baby on the clever design of [Kilian Gosewisch]’s FreeDeck, and they ended up working together to improve it with a dedicated PCB.

The brains of the operation is an Arduino Pro Micro, which addresses each screen individually via two 74HC4051 mux ICs. Thanks to an SD card module, there’s no need to flash the ‘duino every time you want to change a shortcut or its picture. Even if this deck doesn’t hold up forever, it won’t break the bank to build another one. Poke past the break for the build video, which has all the links you’d need to make your own, including a handy configurator.

There’s more than one way to do a visual macro pad. Here’s one that uses a single screen and splits it Brady Bunch style to match the matrix.

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Open-Source Grinder Makes Compression Screws For Plastic Extruders Easy

In a world that’s literally awash in plastic waste, it seems a pity to have to buy fresh rolls of plastic filament to feed our 3D-printers, only to have them generate yet more plastic waste. Breaking that vicious cycle requires melding plastic recycling with additive manufacturing, and that takes some clever tooling with parts that aren’t easy to come by, like the compression screws that power plastics extruders.

This open-source compression screw grinder aims to make small-scale plastic recyclers easier to build. Coming from the lab of [Joshua Pearce] at the Michigan Technological University in collaboration with [Jacob Franz], the device is sort of a combination of a small lathe and a grinder. A piece of round steel stock is held by a chuck with the free end supported by bearings in a tailstock. On the bed of the machine is an X-Y carriage made of 3D-printed parts and pieces of electrical conduit. The carriage moves down the length of the bed as the stock rotates thanks to a pulley and a threaded rod, carrying a cordless angle grinder with a thick grinding wheel. A template attached to the front apron controls how deep the grinder cuts as it tracks along the rod; different templates allow the screw profile to be easily customized. The video below shows the machine in action and the complicated screw profiles it’s capable of producing.

We’ve seen lots of homebrew plastic extruders before, most of which use repurposed auger-type drill bits as compression screws. Those lack the variable geometry of a proper compression screw, so [Joshua] and [Jacob] making all the design documents for this machine available should be a boon to recycling experimenters.

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Your Own Electronic Drum Kit

[Jake_Of_All_Trades] wanted to take up a new drumming hobby, but he didn’t want to punish his neighbors in the process. He started considering an electric drum kit which would allow him to practice silently but still get some semblance of the real drumming experience.

Unfortunately, electric drum kits are pretty expensive compared to their acoustic counterparts, so buying an electric kit was a bit out of the question. So, like any good hacker, he decided to make his own.

He found a pretty cheap acoustic drum kit on Craigslist and decided to convert it to electric. He thought this would be a perfect opportunity to learn more about electric drum kits in general and would allow him to do as much tweaking as he wanted to in order to personalize his experience. He also figured this would be a great way to get the best of both worlds. He could get an electric kit to practice whenever he wanted without disturbing neighbors and he could easily convert back to acoustic when needed.

First, he had to do a bit of restorative work with the cheap acoustic kit he found on eBay since it was pretty worn. Then, he decided to convert the drum heads to electric using two-ply mesh drum heads made from heavy-duty fiberglass screen mesh. The fiberglass screen mesh was cheap and easy to replace in the event he needed to make repairs. He added drum and cymbal triggers with his own DIY mechanism using a piezoelectric element, similar to another hack we’ve seen. These little sensors are great for converting mechanical to electrical energy and can feed directly into a GPIO to detect when the drum or cymbal was struck. The electrical signal is then interpreted by an on-board signal processing module.

All he needed were some headphones or a small amplifier and he was good to go! Cool hack [Jake_Of_All_Trades]!

While you’re here, check out some of our best DIY musical projects over the years.

Software Defined Radio Academy Goes Virtual

They say every cloud has a silver lining. It’s hard to find a positive among all the bad news about the current global pandemic, but it has pushed more conferences and events to allow online participation either live or after the fact. A case in point: The Software Defined Radio Academy’s annual event is all on a YouTube channel so you can attend virtually.

Not all the videos are there yet, but the keynote along with some very technical talks about techniques ranging from FPGAs to spectrum monitoring and spectral correlation density — you can see that video, below. We presume you’ll eventually be able to watch all the presentations listed in the program.

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This Freezer Failure Alarm Keeps Your Spoils Unspoiled

Deep freezers are a great thing to have, especially when the world gets apocalyptic. Of course, freezers are only good when they’re operating properly. And since they’re usually chillin’ out of sight and full of precious goods, keeping an eye on them is important.

When [Adam] started looking at commercial freezer alarms, he found that most of them are a joke. A bunch are battery-powered, and many people complain that they’re too quiet to do any good. And you’d best hope that the freezer fails while you’re home and awake, because they just stop sounding the alarm after a certain amount of time, probably to save battery.

If you want something done right, you have to do it yourself. [Adam]’s homemade freezer failure alarm is a cheap and open solution that ticks all the boxen. It runs on mains power and uses a 100dB piezo buzzer for ear-splitting effectiveness to alert [Adam] whenever the freezer is at 32°F/0°C or above.

If the Arduino loses sight of the DHT22 temperature sensor inside the freezer, then the alarm sounds continuously. And if [Adam] is ever curious about the temperature in the freezer, it’s right there on the 7-segment. Pretty elegant if you ask us. We’ve got the demo video thawing after the break, but you might wanna turn your sound down a lot.

You could assume that the freezer is freezing as long as it has power. In that case, just use a 555.

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