Friday Hack Chat: Fire And Cars

July 4, 2018 by Brian Benchoff 1 Comment

Summer is here, and it’s time for the question on everyone’s mind: how are they going to get the fuselage of a 747 from the California desert to Burning Man? You can’t put it on a train, and it’s much wider than any truck.

This Friday, we’re not going to be answering the modern-day riddle of the Sphinx, but we are going to the talking about other art cars. For this week’s Hack Chat, we’re going to be discussing dragons made out of school buses and pyrotechnics.

Our guest for this Hack Chat will be [Kevin Bracken], best known as the founder of International Pillow Fight Day, but now he’s the project lead fo Heavy Meta, Canada’s largest art car and fire-breathing dragon sculpture/stage. Heavy Meta is a 30-foot long mutant vehicle with flame effects and a 15,000 watt sound system. It’s also the 3tress, a 2,000 square foot workshop founded with the purpose of building this gigantic art car, and it’s the Toronto Art Car Community, a group of people tasked with manufacturing gigantic lumbering behemoths.

Kevin will be discussing how the Heavy Meta crew transformed a GMC school bus into a dragon, how the team learned to build flame effects, how the pneumatics work, and what it’s like to be on tour with half a dozen Maker Faires.

During this Hack Chat, we’ll be talking about:

What an art car is
How do you make the electronics
What precautions do you take to keep it working on the road
How do you control flame effects
What are the legal and regulatory considerations of art cars

You are, of course, encouraged to add your own questions to the discussion. You can do that by leaving a comment on the Hack Chat Event Page and we’ll put that in the queue for the Hack Chat discussion.

Our Hack Chats are live community events on the Hackaday.io Hack Chat group messaging. This week is just like any other, and we’ll be gathering ’round our video terminals at noon, Pacific, on Friday, July 6th. Here’s a clock counting down the time until the Hack Chat starts.

Click that speech bubble to the right, and you’ll be taken directly to the Hack Chat group on Hackaday.io.

You don’t have to wait until Friday; join whenever you want and you can see what the community is talking about.

Neat 3D Printer Hack Makes Printing Multiples Possible

July 4, 2018 by Richard Baguley 24 Comments

One of the promises of 3D printing is that you can mass produce objects at home, printing out multiple copies of whatever you want. Unfortunately, the reality is a bit different: once you have printed something out, you usually need to remove it manually from the print bed. Unless you are [Replayreb], that is: he’s come up with a neat hack to remove a print from the print bed by using a custom bit of G-code to move the print head to knock the print off, into a waiting box.

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Retrotechtacular: Constructing A Car Engine

July 4, 2018 by Jenny List 18 Comments

Oxford is a city world-famous for its university, and is a must-see stop on the itinerary of many a tourist to the United Kingdom. It features mediaeval architecture, unspoilt meadows, two idylic rivers, and a car plant. That’s the part the guide books don’t tell you, if you drive a BMW Mini there is every chance that it was built in a shiny new factory on the outskirts of the historic tourist destination.

A 1930s Morris Ten Series II. Humber79 [CC BY-SA 3.0].

The origins of the Mini factory lie over the road on a site that now houses a science park but was once the location of the Morris Motors plant, at one time Britain’s largest carmaker. In the 1930s they featured in a British Pathé documentary film which we’ve placed below the break, part of a series on industry in which the production of an internal combustion engine was examined in great detail. The music and narration is charmingly of its time, but the film itself is not only a fascinating look inside a factory of over eight decades ago, but also an insight into engine manufacture that remains relevant today even if the engine itself bears little resemblance to the lump in your motor today.

Morris produced a range of run-of-the-mill saloon cars in this period, and their typical power unit was one of the four-cylinder engines from the film. It’s a sidevalve design with a three-bearing crank, and it lacks innovations such as bore liners. The metallurgy and lubrication in these engines was not to the same standard as an engine of today, so a prewar Morris owner would not have expected to see the same longevity you’d expect from your daily.

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A Pick-And-Place That Is A Work Of Art

July 4, 2018 by Jenny List 8 Comments

It’s a Holy Grail among hackerspaces, the possession of a pick-and-place machine. These robotic helpers for placing surface-mount components on PCBs are something of a gateway to electronic production, but they can carry a fearsome cost. Happily for the cash-strapped would-be electronic manufacturer, it is possible to build a pick-and-place for yourself. [Mcuoneclipse] has demonstrated this with a rather impressive build that works with the freely available OpenPnP software.

Superficially it shares much with what you might expect from a small CNC mill, in that it has a frame made from extruded aluminium that carries rails that trace an X and a Y axis supporting a tool head. But instead of a blade it has a box made from laser-cut ply that contains a camera and a vacuum pick-up tool that can collect a component from the tapes and deposit it in the correct point on the board. At the machine’s heart is a Smoothieboard, and the work is done by an assortment of solenoid valves and actuators. A huge amount of attention to detail has been paid to this build, with a holder for all the interchangeable nozzles for different component sizes, laser-cut mountings for all the motorised components, and automatic feeders for the SMD tapes all being carefully designed and built. Several iterations of the design are presented, in particular around the head itself which has passed through more than one form to remove as much vibration as possible. But don’t take it from us, have a look at the video we’ve pasted in below the break.

This isn’t the first pick-and-place machine we’ve brought you here at Hackaday. If you already have a 3D printer, would you consider this upgrade?

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The Electric Vehicles Of EMF Camp: A Sinclair C5, (Almost) As It Should Have Been

July 4, 2018 by Jenny List 40 Comments

Most Hackaday readers will have heard of [Clive Sinclair], the British inventor and serial entrepreneur whose name appeared on some of the most fondly-recalled 8-bit home computers. If you aren’t either a Sinclair enthusiast or a Brit of a Certain Age though, you may not also be aware that he dabbled for a while in the world of electric vehicles. In early 1985 he launched the C5, a sleek three-wheeler designed to take advantage of new laws governing electrically assisted bicycles.

The C5 was a commercial failure because it placed the rider in a vulnerable position almost at road level, but in the decades since its launch it has become something of a cult item. [Rob] fell for the C5 when he had a ride in one belonging to a friend, and decided he had to have one of his own. The story of his upgrading it and the mishaps that befell it along the way are the subject of his most recent blog post, and it’s not a tale that’s over by any means.

The C5 was flawed not only in its riding position, the trademark Sinclair economy in manufacture manifested itself in a minimalist motor drive to one rear wheel only, and a front wheel braking system that saw bicycle calipers unleashed on a plastic wheel rim. The latter was sorted with an upgrade to a disc brake, but the former required a bit more work. A first-generation motor and gearbox had an unusual plywood housing, and the C5 even made it peripherally into our review of EMF Camp 2016, but it didn’t quite have the power to start the machine without pedaling. Something with more grunt was called for, and it came in the form of a better gearbox which once fitted allowed the machine to power its way to the Tindie Cambridge meetup back in April. Your scribe had a ride, but all was not well. After a hard manual pedal back across Cambridge to the Makespace it was revealed that the much-vaunted Lotus chassis had lived up to the Sinclair reputation for under-engineering, and bent. Repairs are under way for the upcoming EMF Camp 2018, where we hope we’ll even see it entering the Hacky Racers competition.

Tie-Dyed Filament Sings With Color

July 3, 2018 by Sonya Vasquez 9 Comments

Manufacturers dye all sorts of 3D printer filaments on their factory lines; why can’t we? [Richard] takes this idea one step further by creating his own custom multicolored reels of nylon. Printing with these reels produces a vibrant pattern that simply demands our attention and begs us to ask: how on earth..?

[Richard’s] tie-dye adventure is cleanly documented on the blog. He simply spools a reel of nylon together and dyes subsections of the spool with a different color. With the filament “paletted” to taste, parts pop of the printer with an eye-catching rib pattern of color.

It’s worth mentioning that nylon is extremely hygroscopic, and dyeing filament in a bath full of colored liquid is sure to get it full of moisture. Then again, nylon’s capacity to absorb water might be why it dyes so well. Nevertheless, filament must be oven-dried (or equivalent) for a successful print. Post-drying, [Richard] doesn’t seem to be having any printing problems, and the results speak for themselves.

3D printers might be frequent fliers on these pages, but we still love seeing small modifications that enhance the visual appeal. What’s more, this trick delivers spectacular results with no modifications to the printer itself. Then again, if this job sounds like just too much work for you, we’d suggest using a sharpie.

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An E-Bike Battery Pack Without Spot Welding

July 3, 2018 by Dan Maloney 44 Comments

In somewhat of a departure from their normal fare of heavy metal mods, [Make It Extreme] is working on a battery pack for an e-bike that has some interesting design features.

The guts of the pack are pretty much what you’d expect – recovered 18650 lithium-ion cells. They don’t go into details, but we assume the 52 cells were tested and any duds rejected. The arrangement is 13S4P, and the cells are held in place with laser-cut acrylic frames. Rather than spot weld the terminals, [Make It Extreme] used a series of strategically positioned slots to make contacts from folded bits of nickel strip. Solid contact is maintained by cap screws passing between the upper and lower contact frames. A forest of wires connects each cell to one of four BMS boards, and the whole thing is wrapped in a snappy acrylic frame. The build and a simple test are in the video below.

While we like the simplicity of a weld-less design, we wonder how the pack will stand up to vibration with just friction holding the cells in contact. Given their previous electric transportation builds, like this off-road hoverbike, we expect the pack will be put to the test soon, and in extreme fashion.

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