The hairclip-embedded tool being used on a Tiger 99x game console, clipped onto a spot where the plastic ribbon meets the LCD panel itself, heating it up

World’s Smallest Hair Straightener For Fixing Old LCD Ribbons

March 19, 2022 by Arya Voronova 8 Comments

[Stephen] writes to us about an LCD repair tool he has created. We’ve all seen old devices with monochrome LCDs connected by thin film, where connections between the PCB and the LCD have deteriorated and the LCD would no longer show parts of the picture. This is a connection heating gadget, that [Stephen] affectionately dubs as World’s Smallest Hair Straightener, made specifically to bring cool old tech back to life.

A resin-printed mold houses a coil of Kanthal wire, easy to source and simple to make. He reuses a hair clip as a housing for the heating element, which also provides pressure needed to squish the film-printed conductive traces into the LCD as the adhesive melts. High-temperature epoxy brings the two together, and with a variable power supply, this tool successfully brought an old Tiger 99x handheld back to life.

This hack was made possible, in part, because of [JohnDevin Duncan] in Hackaday comment section sharing his experience on repairing LCD ribbons back in 2015, giving valuable insights on the problem that we initially thought would be solve-able with a soldering iron. The knowledge shared was distilled by [Stephen] into a tool that we all can now use when we encounter a device we really, really want to revive.

Last time we covered this topic, quite a few hackers popped up with their stories and suggestions. Old game console fix stories are a staple here on Hackaday, a few pop to mind – this high-effort trace repair of a water-damaged GameBoy cartridge, a badly designed NES cartridge socket reinvention, and this GameBoy LCD sunburn damage restoration guide.

Sensor Playground Keeps Track Of Indoor Air Quality Through The Cloud

March 19, 2022 by Robin Kearey 8 Comments

When [tdw] wasn’t feeling well one day, his wife suggested that it might be due to poor air quality in their home. While an ordinary person could have simply opened a window after hearing such an idea, [tdw] instead showed his true hacker spirit and set about measuring the indoor air quality. He began by designing a simple PCB to measure CO2 and volatile organic compound (VOC) levels, but eventually broadened his scope to end up with the Sensor Playground: a plug-and-play platform to read out various sensors and store the results in the cloud.

Deliberately designed to be easy to assemble with minimal soldering skills, the Sensor Playground consists of a big two-layer PCB onto which various modules can be plugged. It supports either an ESP32 DevKit or an Adafruit Feather module to provide processing power, and provides sockets for a bunch of sensors, conveniently wired with power and SPI or I2C. It also provides a rotary encoder and two buttons for user input. All source files are available on [tdw]’s GitHub page, ready to be applied to any kind of sensing task.

[tdw] set up his Sensor Playground with sensors measuring CO2, VOC, PM2.5 (particulate matter), as well as temperature and relative humidity. A web interface allows anyone to track these measurements in real-time. The open and modular design should make it easy to extend this system with various other sensor types: we can imagine that things like solar irradiation, outside temperature and wind speed would also add useful data to the mix. Perhaps even a Geiger counter to keep track of radiation levels?

As indoor air quality sensors go, this one is definitely comprehensive and easy to use. We’ve featured other air quality sensors before, some of which also link their data to the cloud.

A Sinclair ZX81 Clone Still Has The Power To Fascinate

March 15, 2022 by Jenny List 26 Comments

The golden age of 8-bit computing brought us pixelated graphics in bright colours, accompanied of course by chiptune music. This aesthetic is strong enough to define a collective image of a generation’s youth, even if the 1980s reality had much more of the tired 1970s leftovers about it. The truth was that not all popular 8-bit machines had colour, sound, or good graphics, and among these limited-capability machines was Sir Clive Sinclair’s ZX81. With a Z80, 1k of RAM, a membrane keyboard, and not much else, it helped set the stage for the hugely popular ZX Spectrum which followed it. The fun’s not over though, as [Augusto Baffa] demonstrates with his modern recreation of a machine that can switch between the ’81 and its less-popular ZX80 predecessor.

Rather than a Eurocard-sized mainboard and membrane keypad, this clone copies the ZX80 with a full-sized mainboard the front of which carries the keyboard contacts. It also eschews the ULA found in the ’81 for discrete TTL. It’s based upon the venerable Grant Searle design for a homebuilt Sinclair computer, and all of the files for this version can be found in a GitHub repository.

There is a lot to be said for the ZX81 as a model for retrocomputer experimentation, because of its extreme simplicity. It may have been no great shakes in the computing department compared to many of its competitors, but it remains possibly one of the easiest of the bunch whose operation to completely understand. Also we like it for that paltry 1k of memory, teaching kids about memory constraints is a good thing in our book.

We’ve featured the diminutive ZX more than once, including a couple of years ago in our April Fools coverage.

Kia Recalls Cars Over Airbag Controller Assembly Issue

March 9, 2022 by Chris Lott 26 Comments

Last month Kia Motors announced a large recall due to possibly defective airbag controller units (ACU). The recall spans many models and model years — in the United States alone it covers over 400K cars, and over half a million cars worldwide. From the NHTSA report we learn that the problem happened at assembly when the cover of some ACUs interfered with the pins of an EEPROM chip. This can cause some of the pins to open-circuit. If your car had this problem, a warning light would come on, but more seriously, the airbags would not deploy in an accident. Kia estimates that less than 1% of the cars using this ACU have this issue. Cars which have this fault will get a new ACU, and other cars will get a firmware upgrade to keep this from happening should the EEPROM pins break loose in the future.

We think this EEPROM is used for logging errors and crash events, and is therefore not in the critical path for airbag deployment. The original firmware apparently prevented deployment if the EEPROM had a fault. Presumably, after this patch, if pins break in the future, the fault indicator still lights up but you’ll have functioning airbags.

It’s not clear if these broken EEPROM pin solder joints were present from the start and the factory test procedures didn’t catch the problem. Or did the pins left the factory intact and were subsequently broke due to bumps and vibrations. Hardware issues aside, having safety critical firmware perform its primary function even when faults exist in non-essential parts of the circuit seems like a requirement that should have been applied to the ACU from the beginning.

This is a reminder of the importance of enclosure design and making sure your PCB layouts take into account all clearances necessary for the entire assembly. How many times have you got your PCB back and realized you forgot to even put mounting holes?

We covered a similar issue a couple of years ago regarding the Takata airbag fiasco. If you have a Kia, this form on their website tells you whether your vehicle is subject to the recall or not.

Vintage Meter Repair? It’s Easier With X-Rays

March 6, 2022 by Donald Papp 18 Comments

Here’s an interesting and detailed teardown and repair of a Keithley 2001 7.5 Digit multimeter that is positively dripping with detail. It’s also not every day that we get to see someone using x-ray imaging to evaluate the extent of PCB damage caused by failed electrolytic capacitors.

Dark area is evidence of damage in the multi-layer PCB.

Sadly, this particular model is especially subject to that exact vintage electronics issue: electrolytic capacitor failure and leakage. These failures can lead to destroyed traces, and this particular unit had a number of them (in addition to a few destroyed diodes, just for good measure.) That’s where the x-ray machine comes in handy, because some of the damage is hidden inside the multi-layer PCBs.

[Shahriar], perhaps best known as [The Signal Path], narrates the entire process of fixing up the high-quality benchtop multimeter in a video, embedded below (or you can skip directly to the x-ray machine being broken out.) [Shahriar] was able to repair the device, thanks in part to it being in relatively good shape, and having the right tools available. Older electronics are not always so cooperative; the older a device is, the more likely one is to run into physical and logical standards that no longer exist.

Continue reading “Vintage Meter Repair? It’s Easier With X-Rays” →

Compressed Air Jumping Shoes Are Not For The Faint-Hearted

March 3, 2022 by Dave Rowntree 30 Comments

[Ian Charnas] has taken a short break from building things that might injure himself, by building something that could injure somebody else instead. (Video, embedded below) Well, hopefully not anyway. After working with YouTuber [Tyler Csatari] on a few ideas, [Tyler] was insistent on getting some power-assisted jumping shoes, so [Ian] set to work mounting some compressed-air powered pistons to a pair of walking shoes. With a large backpack housing the 200 PSI air cylinder, control valves and timers. The whole affair looks solidly constructed, if a little ungainly, but does seem to work surprisingly well.

After some initial calculations of how much force each piston could exert before risking leg injury, he found that whilst it did work, to an extent, the pressure required was beyond the capability of the compressor they had on hand. After a shopping trip, a bigger compressor was located, but that still needed a modification to get anywhere near its maximum 200 psi rating. The thing is, that modification was to bypass the regulator and the safety valve, and this is definitely something you don’t want to be making a habit of. Compressed air systems like this can hold quite a bit of an explosion potential if pushed beyond reasonable limits, and care needs to be taken to keep things within safe bounds.

Cost-wise, [Ian] does mention a figure of around $3,000 USD making it a bit of a pricey project, but hey a YouTuber’s paying the bill, so it must just be a drop in the ocean for them?

Just to illustrate how useful compressed air is as a method of storing energy, here’s a compressed-air powered helicopter, and a 3D printed wankel rotary engine, which must’ve been tough to dial in and get working!

Continue reading “Compressed Air Jumping Shoes Are Not For The Faint-Hearted” →

Modules described in the article (two copies of the challenge shown, so, two lines of modules)

Spaceship Repair CTF Covers Hardware Hacker Essentials

March 3, 2022 by Arya Voronova 15 Comments

At even vaguely infosec-related conferences, CTFs are a staple. For KernelCon 2021, [Tyler Rosonke] resolved to create a challenge breaking the traditions, entertaining and teaching people in a different way, while satisfying the constraints of that year’s remote participation plans. His imagination went wild in all the right places, and a beautifully executed multi-step hardware challenge was built – only in two copies!

Story behind the challenge? Your broken spaceship has to be repaired so that you can escape the planet you’re stuck on. The idea was to get a skilled, seasoned hacker solving challenges for our learning and amusement – and that turned out to be none other than [Joe “Kingpin” Grand]!

The modules themselves are what caught our attention. Designed to cover a wide array of hardware hacker skills, they cover soldering, signal sniffing, logic gates, EEPROM dumping and more – and you have to apply all of these successfully for liftoff. If you thought “there’s gotta be a 555 involved”, you weren’t wrong, either, there’s a module where you have to reconfigure a circuit with one!

KernelCon is a volunteer-driven infosec conference in Omaha, and its 2022 installment starts in a month – we can’t wait to see what it brings! Anyone doing hardware CTFs will have something to learn from their stories, it seems. The hacking session, from start to finish, was recorded for our viewing pleasure; linked below as an hour and a half video, it should be a great background for your own evening of reverse-engineering for leisure!

This isn’t the first time we’ve covered [Tyler]’s handiwork, either. In 2020, he programmed a batch of KernelCon badges while employing clothespins as ISP clips. Security conferences have most certainly learned just how much fun you can have with hardware, and if you ever need a case study for that, our review of 2019 CypherCon won’t leave you hanging.

Continue reading “Spaceship Repair CTF Covers Hardware Hacker Essentials” →