Shop-Made Fixture Turns Out Dream Welds

November 10, 2017 by 14 Comments

You can tell a lot about a person by the company they keep, and you can tell a lot about a craftsman by the tools and jigs he or she builds. Whether for one-off jobs or long-term use, these ad hoc tools, like this tubing rotator for a welding shop, help deliver results beyond the ordinary.

What we appreciate about [Delrin]’s tool is not how complex it is — with just a motor from an old satellite dish and a couple of scooter wheels, it’s anything but complicated. What we like is that to fabricate some steering links, each of which required three passes of TIG welding to attach a threaded bung to the end of a rod, [Delrin] took the time to build just the tool for the job. The tools slowly rotates the rod, letting the welder keep the torch in one position as the workpiece moves under it. The grounding method is also simple but clever — just a wide strap of braid draped over the rod. The result is some of the prettiest and most consistent welds we’ve seen in a while, and with an order for 28 steering links, it ought to be a huge time saver.

It may be time for a little more TIG welding love around here. Sure, we’ve covered the basics of oxy-acetylene welding, and even talked about brazing aluminum. Perhaps your humble Hackaday writer will take the plunge into a new TIG welder and report from a newbie’s perspective. You know, for science.

[via r/welding]

Hacking When It Counts: Prison Locksmithing

November 10, 2017 by 28 Comments

In 1978, Tim Jenkin was a man living on borrowed time, and he knew it. A white South African in his late 20s, he had been born into the apartheid system of brutally enforced racial segregation. By his own admission, he didn’t even realize in his youth that apartheid existed — it was just a part of his world. But while traveling abroad in the early 1970s he began to see the injustice of the South African political system, and spurred on by what he learned, he became an activist in the anti-apartheid underground.

Intent on righting the wrongs he saw in his homeland, he embarked on a year of training in London. He returned to South Africa as a propaganda agent with the mission to spread anti-apartheid news and information to black South Africans. His group’s distribution method of choice was a leaflet bomb, which used a small explosive charge to disperse African National Congress propaganda in public places. Given that the ANC was a banned organization, and that they were setting off explosives in a public place, even though they only had a few grams of gunpowder, it was inevitable that Jenkin would be caught. He and cohort Steven Lee were arrested, tried and convicted;  Jenkin was sentenced to 12 years in prison, while Lee got eight.

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Cat Feeder Has Steampunk Flair And A GMail Account

November 10, 2017 by 31 Comments

While it is often said that “necessity is the mother of invention”, we can’t say that’s always been our experience here at Hackaday. You won’t need to search too long before you find a project or hack on this site that definitely falls out of the realm of strict necessity. But that’s part of the fun, there’s a reason this site isn’t called AppropriateUseOfTime.com

But when [Sam Storino] couldn’t seem to stop his cats from howling for their supper at 3:00 AM, he had the perfect opportunity to fulfill that age-old wisdom. Not only did he manage to turn a trip to the plumbing isle of his local home improvement store into a very Steampunk-looking automatic cat feeder, but he also found the time to write up an exceptionally detailed series of blog posts on what he learned during the process.

The heart of the machine is everyone’s favorite Linux board, the Raspberry Pi. You might be thinking the Pi is overkill for a simple timer, and you’d be right. Rather than just dump the food out on a set schedule, [Sam] decided to get a little fancy and come up with some Python scripts that will monitor a GMail inbox and activate the feeder hardware when it receives an email with the title “feed cats”. He then uses IFTTT to send the appropriately named email to the GMail account of his cat feeder on a specific schedule. Hey, nobody said necessity was the mother of straightforward invention.

In the final post of the series, [Sam] goes over the hardware side of the device. Copper pipe makes up the frame, which holds a commercial off-the-shelf dry food dispenser. The feeder was designed for manual operation, but by attaching a continuous rotation servo [Sam] can spin it up and dump a pre-measured amount of food via the Pi’s GPIO pins. The addition of some PVC pipe and fittings takes the food and (at least in theory) divides it equally between the two cat bowls below.

If you think [Sam] may have put a bit more thought than was necessary into something as simple as feeding his pets, keep in mind that he’s in exceptionally good company. Paging through the archives, it seems the intersection of felines and hackers is littered with gloriously complex contraptions.

An Awesome Open Mechanical Keyboard

November 10, 2017 by 19 Comments

Who doesn’t want a little added functionality to their  lives? Feeling a few shortcut keys would make working in Eagle a bit smoother, [dekuNukem] built his own programmable mechanical keypad: kbord.

It sports vibrant RGB LED backlight effects with different animations, 15 keys that execute scripts — anything from ctrl+c to backdoors — or simple keystrokes, up to 32 profiles, and a small OLED screen to keep track of which key does what!

kbord is using a STM32F072C8T6 microcontroller for its cost, speed, pins, and peripherals, Gateron RGB mechanical keys — but any clear key and keycaps with an opening for the kbord’s LEDs will do — on a light-diffusing switch plate, and SK6812 LEDs for a slick aesthetic.

Check out the timelapse video tour of his build process after the break! (Slightly NSFW, adolescent humor for a few seconds of the otherwise very cool video. Such is life.)

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Weatherproof Pi Looks Up So You Don’t Have To

November 9, 2017 by 27 Comments

Skywatching is a fascinating hobby, but does have the rather large drawback of needing to be outside staring at the sky for extended periods of time. Then there’s the weather to contend with, even if you’ve got yourself a nice blanket and it isn’t miserably cold, there might be nothing to see if cloud cover or light pollution is blocking your view.

Highly scientific testing procedure.

To address these issues, [Jason Bowling] decided to put a Raspberry Pi in a weatherproof enclosure and use it as a low-cost sky monitoring device. His setup uses the No-IR camera coupled with a cheap wide-angle lens designed for use with smartphone camera. The whole setup is protected from the elements by a clear acrylic dome intended for a security camera, and a generous helping of gasket material. Some experiments convinced [Jason] to add a light pollution filter to the mix, which helped improve image contrast in his less than ideal viewing area.

The software side is fairly straightforward: 10 second exposures are taken all night long, which can then be stitched together with ffmpeg into a timelapse video. [Jason] was concerned that the constant writing of images to the Pi’s SD card would cause a premature failure, so he set it up to write to a server in the house over SSHFS. Adding a USB flash drive would have accomplished the same thing, but as he wanted to do the image processing on a more powerful machine anyway this saved the trouble of having to retrieve the storage device every morning.

This isn’t the first time [Jason] has used a Pi to peer up into the heavens, and while his previous attempts might not be up to par with commercial offerings, they definitely are very impressive considering the cost of the hardware.

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Home Server Has AMD CPU And IKEA Case

November 9, 2017 by 39 Comments

Readers who took part in the glory days of custom PC building will no doubt remember the stress of having to pick a case for their carefully-curated build. You may have wanted to lower the total cost a bit by getting a cheap case, but then you’d be stuck looking at some econo-box day in and day out. Plus, how do you post pictures online to boast about your latest build if there are no transparent windows and a lighting kit?

While some may have spent more time choosing their lighted case fans than their optical drive, [Miroslav Prašil] was surely not one of them. When he decided to build a new NAS for his home network, [Miroslav] decided he wanted to put all his money into the device’s internals, and house his build in a wooden storage crate from IKEA. While the low cost was certainly a major factor in the decision, it turns out the crate actually offers a decent amount of room for hardware components. As an added bonus, it doesn’t look completely terrible sitting out in the living room.

In a detailed series of posts on his blog, [Miroslav] walks us through the entire process of building what he has come to call the “NAScrate”. Wanting gigabit Ethernet and a real SATA controller, [Miroslav] went for the ASRock C70M1, a Mini-ITX board with integrated dual-core AMD processor. While not exactly a powerhouse, it will certainly wipe the floor with the fruit-inspired single board computers that so often dominate these types of builds.

To get his clearances worked out, [Miroslav] rendered the entire build in OnShape, which gave him enough confidence in his design to move on to actual construction. The build involves several 3D printed parts, most notably some clever hard drive mounting brackets which allow the drives to be stacked into a space-saving arrangement while still leaving room for airflow between them.

[Miroslav] deftly avoids any religious debates by leaving off his particular choice for software and operating system on his newly constructed NAS, but he does mention that something like FreeNAS would be a logical choice.

While this may be the first wooden one we’ve covered so far, home servers in general are a favorite project for hackers, from budget-friendly scratch builds all the way up to re-purposed enterprise hardware.

3D Printed Helical Satcom Feed

November 9, 2017 by 27 Comments

With the advent of cheap software defined radios made popular by the RTL-SDR project a few years back, satellite communications are now within the budget of even the most modest hacker. For $20 USD you can get a USB SDR module that is more than capable of receiving signals from any number of geosynchronous satellites, but you’ll need something a little more robust than rabbit ears to pick up a signal broadcast from over 22,000 miles away.

Building a satellite-capable antenna isn’t necessarily difficult, but does involve a fair bit of arcane black magic and mathematics to do properly; something that can scare away those new to the hobby. But by using a 3D printed mandrel, [Tysonpower] has come up with a feed you can build and mount on a standard dish without having to take a crash course in antenna theory. [Tysonpower] reports the feed has a center frequency 1550 MHz, and works well for reception of Inmarsat, AERO and HRPT signals.

The channel in the 3D printed core of the feed ensures that the inserted wire is of the correct length and in the perfect position for optimal reception. All you need to do is print the core, wrap it with wire, and then solder the end to a connector on a ground-plane that’s nothing more than a sheet of aluminum. [Tysonpower] was even kind enough to model up a mount that will allow you to bolt this feed to a standard satellite dish.

We’ve previously covered using RTL-SDR to receive Inmarsat transmissions, and hardware for the Outernet project, both of which would be great applications for an antenna like this.

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