Building An Ultralight Out Of Foam In A Basement

August 14, 2017 by Brian Benchoff 50 Comments

[Peter Sripol] is something of a legend in the DIY RC aircraft crowd. He’s friends with Flite Test, and there he built an enormous RC cargo plane that could easily carry a small child aloft. Now, [Peter] is aiming a bit higher. He’s building an ultralight — a manned ultralight — in his basement. It’s made out of insulation foam.

Yes, this ultralight is constructed out of insulation foam, but you can think of that as just a skin. The real structure here comes from a wooden frame that will be fiberglassed. The design of this aircraft is an electric, twin-engine biplane. The relevant calculations have already been done, and [Peter] is already flying an RC scale model of this craft. So far, everything is not as sketchy as it could be.

As with any, ‘guy builds an airplane in his basement’ story, there must be a significant amount of time dedicated to the legality, practicality, and engineering of said plane. First off, the legality. [Peter] is actually building an ultralight under Part 103. The certifications for a Part 103 ultralight are much more lenient than the next step up in FAA-certified aircraft, a light sport or experimental aircraft. An ultralight is not required to have an airworthiness certification, and pilots of ultralights are not required to pass any tests of aeronautical knowledge or hold a medical certificate. Yes, legally, any moron can jump in an ultralight and fly. Think about that the next time someone brings up the Part 107 ‘drone’ certification.

Next, the practicality and engineering. [Peter]’s plane can weigh a maximum of 254 pounds, and should not be capable of more than 55 knots in full power level flight, while having a stall speed that does not exceed 24 knots. This is slow for a Cessna, but just about right for the gigantic remote-controlled planes [Peter] has already built. A few years ago, [Peter] built a gigantic remote-controlled cargo plane out of what is basically foam board and a few aluminum tubes. The construction of [Peter]’s ultralight will be a highly refined version of this. He’s using foam insulation sheets for the body of the fuselage, reinforced with plywood and poplar struts. This foam and wood build will be wrapped with carbon fiber and fiberglass sheet, epoxied, and hopefully painted with flames on the side.

The use of poplar is a bit curious for an ultralight aircraft. For the last hundred years, the default wood for aircraft has been either spruce or douglas fir. The reason for this choice is the strength to weight ratio; spruce and douglas fir have the highest strength to weight ratio of any other wood. Poplar, however, is ultimately stronger and available at his local home improvement store, even though it does weigh a bit more. If [Peter] can keep the weight down in other areas, poplar is an excellent choice due to cost and availability. The video (below) is unclear, but we can only hope [Peter] has read up on the strength of aircraft frames and the orientation of the grain of each structural member.

This is the first video in what will be an amazing build series, and [Peter] hopes to get this thing up in the air by September. If you’re concerned about [Peter]’s safety, he’s also put up a GoFundMe page for a parachute. [Peter]’s going to fly this thing if you complain or concern troll or not, so donate a dollar for the parachute if you’re that concerned.

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Bibles You Should Read: PoC || GTFO

August 14, 2017 by Brian Benchoff 54 Comments

PASTOR LAPHROAIG ANNOUNCES THE PUBLICATION OF WHAT WILL TORMENT THE ACOLYTES OF THE CHURCH OF ROBOTRON! NO MAN SHALL BE SPARED AND THE INQUISITION WILL BEGIN PROMPTLY!

For the last few years, Pastor Manul Laphroaig and friends have been publishing the International Journal of PoC || GTFO. This is a collection of papers and exploits, submitted to the Tract Association of PoC || GTFO, each of which demonstrates an interesting exploit, technique, or software toy in the field of electronics. Imagine, if 2600 or Dr. Dobb’s Journal were a professional academic publication. Add some whiskey and you have PoC || GTFO.

This is something we’ve been waiting a while for. The International Journal of PoC || GTFO is now a real ~~book~~ bible published by No Starch Press. What’s the buy-in for this indulgence? $30 USD, or a bit less if you just want the Ebook version. The draw of the dead tree version of PoC includes a leatherette cover, gilt edges, and the ability to fit inside bible covers available through other fine retailers. There are no rumors of a children’s version with vegetable-based characters.

PoC || GTFO, in reality, is an almost tri-annual journal of reverse engineering, computer science, and other random electronic computational wizardry, with papers (the Proof of Concept) by Dan Kaminsky, Colin O’Flynn, Joe FitzPatrick, Micah Elisabeth Scott, Joe Grand, and other heroes of the hacker world. What does PoC || GTFO present itself as? Applied electrons in a religious tract publication. The tongue is planted firmly in the cheek here, and it’s awesome.

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From Handheld Bandsaw To Shop Bandsaw

August 14, 2017 by Jenny List 19 Comments

If you grow up around a workshop then the chances are that you’ll have the most respect for saws. Formative years being constantly warned by parents about their risks leave an indelible mark on the nascent maker, and leave them visibly less cavalier on the matter than for example other hackspace members. The fact remains that saws offer some of the most ready opportunities for danger in your workshop. But which are the least hazardous? In the workshop near where this is being written, definitely a bandsaw is far preferable to a circular saw when it comes to finger retention.

[Making Stuff] has a portable bandsaw, contained in effect within a large handheld power tool. He’s put up a video detailing how he modified it to serve as a more conventional vertical or horizontal bandsaw, with the addition of a sturdily built welded tubular frame and table.

The video starts with the removal of the plastic surround to the trigger and hand grip, then proceeds through the various stages of cutting, measuring, drilling, and welding. The pivot point is the crank bearing from a bicycle, and in a slightly overcomplex touch the switch is a solid state relay rather than something conventional. The metal work is well executed, and while the engineering is noting special and most Hackaday readers could do similar, it has the compelling quality of a workshop video in which everything is done right and the results are well presented. You might not make this saw, but if you had one it wouldn’t disappoint you. The full video is below the break.

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Filaween 2.0 Is Go

August 14, 2017 by Elliot Williams 3 Comments

[Thomas Sanladerer] is at it again: testing all of the 3D-printer filaments that are fit to print (with). And this year, he’s got a new and improved testing methodology — video embedded below. And have a search for “filaween2” to see what he’s reviewed so far. There’s some sexy filaments in there.

We really love the brand-new impact strength test, where a hammer is swung on a pivot (3D printed, natch), breaks through the part under test, and swings back up to a measurable height. The difference in swing height reflects the amount of energy required to break the test piece. Sweet physics.

[Thomas] ran a similar few-month-long series last year, and we’re stoked to see it return with all the improvements. Here’s to watching oddball plastics melt!

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A Tale Of Two Raft Races

August 13, 2017 by Jenny List 5 Comments

It’s the height of summer in the Northern Hemisphere, and hackers and makers everywhere are letting their hair down and enjoying the hot weather on the water. By coincidence last weekend there were two very different raft races in the European hackspace community, at the SHACamp2017 gathering in the Netherlands the villages competed in a cardboard raft race, while on the other side of the English Channel the various hackspaces in and around London came together in a raft race using more conventional materials.

Some of the SHA entries needed a little help.

The SHA race came about through the happy confluence of a surplus of disposable cardboard tents, a sunny afternoon, and the inviting waters of the Nuldemauw. The aim of the contest was for hacker camp villages to make it from the bank to the end of the boat dock, a distance of about 100m, in a boat made from cardboard there and then at the camp. Meanwhile the London spaces met at City Road Basin in London with their more robust watercraft for a series of races, the aim of which seems to have been to be the first to get their crew disembarked at the other end of the course. and sitting in a chair on the bank.

Full steam ahead for South London Makerspace. Toby *Spark (CC BY-NC-SA 2.0)

In both races the inventiveness of the entrants showed itself in a wide range of boat designs. As you might expect those craft with a wider beam fared better than the far less stable narrower ones, with capsizes a feature at each location. Clear winners in the Netherlands were a pair of German teenagers in a very stable wide raft, while in London it was South London Makerspace’s catamaran that scooped the crown. There is a video of the London race which we’ve placed below the break.

The hackspace and makerspace spirit is at its strongest when bonds are forged between members of different spaces. Skills and capabilities are shared, collaboration opportunities abound. The sight of a bunch of European makers getting wet might serve more as entertainment than edification, but behind it lies an important facet of hackspace culture. If you’ve not yet been the spaces closest to yours, do so. You never know, one day you might end up on a capsizing raft because of it.

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Complete IR Control

August 13, 2017 by Elliot Williams 16 Comments

What can you do with an IR remote? How about anything? Maybe not. We’ll settle for issuing arbitrary commands and controlling tasks on our computer.

The first step in [Fungus]’s hack is straightforward: buy an IR receiver for a buck, plug it into an Arduino, and load up some IR-decoding code. If you haven’t done this before, you owe it to yourself to take some time now. Old IR remotes are very useful, and dead simple, to integrate into your projects.

But here comes the computer-control part. Rather than interpret the codes on the Arduino, the micro just sends them across the USB serial to a laptop. A relatively straightforward X11 program on the (Linux) computer listens for codes and does essentially anything a user with a mouse and keyboard could — that is to say, anything. Press keys, run programs, open webpages, anything. This is great for use with a laptop or desktop, but it’d also be a natural for an embedded Raspberry Pi setup as well.

Hacking the code to do your particular biddings is a simple exercise in monkey-patching. It’s like a minimal, hacked-together, USB version of LIRC, and we like it.

Thanks [CoolerVoid] for the tip!

Hackaday Links: August 13, 2017

August 13, 2017 by Brian Benchoff 29 Comments

We found the most boring man on the Internet! HTTP Status Code 418 — “I’m a teapot” — was introduced as an April Fools Joke in 1998. Everyone had a good laugh, and some frameworks even implemented it. Now, the most boring man on the Internet and chairman of the IETF HTTP working group is trying to get 418 removed from Node and Go. There is an argument to removing code 418 from pieces of software — it gums up the works, and given only 100 code points for a client error, with 30 of them already used, we don’t really have space for a joke. There’s a solution, though: someone has submitted a request to register 418 as ‘I’m a teapot’.

The Travelling Hacker box is a migratory box of random electronic junk. The box has traveled across the United States several times, and earlier this year it started across Canada — from Vancouver to St. Johns — to begin an International journey. The box is now missing, and I’m out. I’m turning this one over to the community. There are now several rogue boxes traveling the world, the first of which was sent from [Sophi] to [jlbrian7] and is now in Latvia with [Arsenijs]. The idea of the Travelling Hacker Box is now up to you — organize your own, and share random electronic crap.

Bluetooth 5 is here, or at least the spec is. It has longer range, more bandwidth, and advertising extensions.

Guess what’s on the review desk? The Monoprice Mini Delta! If you have any questions you’d like answered about this tiny, very inexpensive printer, put them in the comments. I only have some first impressions, but so far, it looks like extending the rails (to make a taller printer) is more difficult than it’s worth. That’s not to say it’s impossible, but with the effort required, I could just print another printer.

Interested in PCB art? [Drew] found someone doing halftone art with PCBs. This is a step up from nickels.

Indiana University is getting rid of some very, very cool stuff in a government auction. This device is listed as a ‘gantry’, but that’s certainly not what it is. There have been suggestions that these devices are a flight sim, but that doesn’t sit quite right either. It’s several thousand pounds of metal, with the minimum bid of $2.00 at the time of this writing. Any guesses on what this actually is?