1921 Ner-A-Car Motorcycle Reborn With Epic Parts Remanufacture

April 7, 2016 by Jenny List 26 Comments

Most of the rusty parts you need to make a motorcycle.

Nobody ever dismantles a working motorcycle.

About ten years ago [Andy Pugh] took possession of a large box of rusty parts that formed most of what had once been a 1921 Ner-a-Car motorcycle. They languished for several years, until in 2014 he was spurred into action and returned to the bike. What followed was a two-year odyssey of rebuilding, restoration, and parts remanufacture, and since [Andy] is an engineer par excellence and an active member of the LinuxCNC community his blog posts on the subject should be a fascinating read for any hardware hacker with an interest in metalwork.

The Ner-a-Car. By Museumsfotografierer (Own work) [Public domain], via Wikimedia Commons

The Ner-a-Car represents one of those eccentric dead-ends in automotive history. Designed in 1918 by an American, [Carl Neracher], its name is a play on both its designer and its construction and it is unique in that its design is closer to the cars of the era than that of a motorcycle. It has a car-style chassis, an in-line engine, and it was the first motorcycle to be produced with hub-centre steering. The rider sits on it rather than astride it, feet-forward, and the car-style chassis gives it a very low centre of gravity. They were manufactured in slightly different versions in both the USA and the UK, and [Andy]’s machine is an early example from the British production line. Not many Ner-a-Cars have survived and parts availability is non-existent, so his work has also had the unusual effect of satisfying a significant portion of world demand for the parts-bin of an entire marque.

It’s usual for the first link in a Hackaday article to be to a page that encompasses the whole project. In this case when there is so much to see and the build is spread across twelve blog posts and nearly two years the link is to [Andy]’s first post in which he describes the project, sets to work on the chassis, and discovers the bent steering arm that probably caused the bike’s dismantling. He’s listed the posts in the column on the right-hand side of the blog, so you can follow his progress through the entire build. The work involved in remanufacturing the parts is to an extremely high standard, from machining press tools to reproduce 1920s footboard pressings through manufacturing authentic 1920s headlight switchgear and metal-spinning new aluminium headlight shells.

[Andy]’s most recent Ner-a-Car post details his trip to France on the completed bike, and tales of roadside repairs of a suddenly-not-working machine that should be familiar to any owner of a vintage internal combustion engine. But considering that the bike spent many decades as a pile of not much more than scrap metal the fact that it is now capable of a trip to France is nothing short of amazing.

This is the first rebuild of a vintage bike from a box of rusty parts we’ve featured here – indeed it could almost be a retrotechtacular piece in its detailed look at 1920s bike design. These pages have however seen many motorcycle related hacks over the years. We particularly like this from-scratch engine build and this gas-turbine bike, but it is the emergency motorcycle build in the desert from a Citroën 2CV car that has us most impressed. Please, ride safe, and keep them coming!

Error Correction Of 3D Printers

April 7, 2016 by Brian Benchoff 42 Comments

From the very first RepRaps to the newest and latest printers off the Makerbot assembly line, nearly every consumer 3D printer has one significant shortcoming: it cannot recover from missed steps, slipped belts, or overheating stepper drivers. Although these are fairly rare problems, it does happen and is purely a product of the ~~closed~~ open-loop control system used in 3D printer firmware.

[Chris Barr] has come up with a rather clever solution to this problem. He’s designed a system that will detect and correct problems with the mechanics of 3D printers. It’s technically not a closed-loop control system, but it does allow him to get the absolute position of a nozzle on the build plate, detects error states, and can automatically calculate the number of motor steps per millimeter. It’s also much simpler than other closed loop control systems we’ve seen in the past, requiring only a few bits and bobs attached to the axes and to the printer controller board.

[Chris]’ system uses a magnetic encoding strip, a single chip, and a little bit of support circuitry. It’s actually not that much different from the moving axis on a desktop inkjet printer. It’s not closed loop, though; the firmware hack is only a ‘basic error correction’ that moves the nozzle back to where it should be. Although this is somewhat of a kludge, it is much simpler than refactoring the entire printer firmware.

In the video below, [Chris] demonstrates his solution for error correcting the printer by jerking his axis around during a print. The nozzle miraculously returns to where it should be, producing a usable part.

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Machines That Build Other Machines

April 6, 2016 by Brian Benchoff 18 Comments

When the RepRap project was founded in 2005, it promised something spectacular: a machine that could build copies of itself. RepRaps were supposed to be somewhere between a grey goo and a device that could lift billions of people out of poverty by giving them self-sufficiency and the tools to make their lives better.

While the RepRap project was hugely successful in creating an open source ecosystem around 3D printers, a decade of development hasn’t produced a machine that can truly build itself. Either way, it’s usually easier and cheaper to buy a 3D printer than to build your own.

[castvee8]’s entry into the 2016 Hackaday Prize does just what the RepRap project promised ten years ago. It’s all about building machines with the ability to reproduce, creating an ecosystem of machines to build household goods. The best part? You can 3D print most of the machines. It’s the RepRap project, but for mills, lathes, microscopes, and routers. It’s an entire shop produced entirely in a 3D printer.

The idea of creating a machine shop from the most basic building materials has been around for a while. At the turn of the last century, concrete lathes and mills bootstrapped industrial economies. Decades later, [David J. Gingery] created a series of books on building a machine shop starting with a charcoal foundry. The idea of building a shop using scrap and the most minimal tools is very old, but this idea hasn’t been updated to the era where anyone can buy a 3D printer for a few hundred dollars.

So far, [castvee8] has a few homemade machine tools on the workbench, including a lathe, a tiny mill easily capable of fabricating a few circuit boards, and a little drill press. They’re all machines that can be used to make other useful items, and all allow anyone to create the devices they need.

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This TARDIS Is An Infrasonic Subwoofer

April 6, 2016 by Jenny List 32 Comments

If you’re a fan of action movies or dance music, you’ll probably be familiar with sub-bass. The moment in those James Bond explosions that thuds through your chest in the movie theatre? That’s the product of a large subwoofer, a tuned pipe housing a speaker working somewhere just above the lower limit of human hearing, in the tens of Hz.

[Mike's] TARDIS final build — [Mike’s] TARDIS final build

But what about sound below the range of human hearing, below 20Hz? You can’t directly hear infrasound, but its presence can have a significant effect on the experience of the listener. [Mike Michaud] was interested in this phenomenon for his home movie setup so built himself an infrasonic subwoofer tuned to 17Hz. Since the resulting cabinet was rather large he disguised it as a vintage UK police telephone box that you’d hardly notice in his basement theater.

A resonant 17Hz speaker horn is a rather inconvenient size for a home theatre, at about 25 feet long. Fortunately there is no need for the horm to be straight, it can be folded into a more convenient enclosure, and that is what [Mike] has done. He used a design published by [lilmike], which folds the horn three times into a more manageable size.

Speaker cabinet construction requires attention to the choice of materials as well as to the driver unit itself, so [Mike] goes into detail on the materials he rejected and his selection of a particular brand of subfloor ply.

He rates the resulting speaker as incredible. His driver is rated for 500 watts but he only has an amplifier capable of serving 100, even with that power he fears for his basement windows. He describes the noise made by the feet of the robots in War Of The Worlds as “little earthquakes” and the general effect as very menacing.

We’ve featured quite a few subwoofers on Hackaday over the years, though with the exception of this rotary device they have mostly been for more conventional sub-bass applications. Here for example is another folded horn. So if sub has become rather run-of-the-mill for you all, how about using it to be entertained by this vortex cannon?

ChaiBot: A Tea Robot Steeped In Utility

April 6, 2016 by Kristina Panos 21 Comments

On the surface, a cup of tea is a simple thing to make. Heat up some water, insert tea leaves, and wait for it to steep. The wait time is a matter of taste, and it is absolutely crucial to remove the bag or infuser before it’s too late. Otherwise, you end up with a liquid that’s almost, but not quite, entirely unlike tea.

[Adrian] and his son would often find themselves lost in conversation during the steeping process and let it go too long. But that was before they built ChaiBot, an automatic tea minder. This fine-looking machine uses an old CD drive to raise and lower the tea bags, which are held by a thin piece of stainless steel mesh. Once the bags are lowered, [Adrian] pours hot water into the cups. The weight of the water is detected by a capacitive sensor under the cup cutouts, and this triggers the timer to start counting down to the perfect cuppa.

One of the coolest features of ChaiBot is the built-in circulation. Every minute, the bags are lifted out briefly and reinserted, disturbing the water so the steeping is more uniform. Since the final step to making great tea is drinking it before it goes cold, ChaiBot sends a push notification to [Adrian]’s phone. Be sure to check out the demo after the break.

Here’s another CD drive-based tea bot we covered a while back. It’s not quite as pretty, but it gets the job done. If you’re not one to wander off while your tea steeps but prefer not to watch a clock, here’s a compact timer that’ll fit in your pocket.

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Get Your Game On: Troy’s TVCoG Hosts VR And Gaming Hackathon

April 6, 2016 by Dan Maloney 1 Comment

Troy New York’s Tech Valley Center of Gravity is following up their January IoT Hackathon with another installment. The April 16-17 event promises to be a doozy, and anyone close to the area with even a passing interest in gaming and AR/VR should really make an effort to be there.

Not content to just be a caffeine-fueled creative burst, TVCoG is raising the bar in a couple ways. First, they’re teaming up with some corporate sponsors with a strong presence in the VR and AR fields. Daydream.io, a new company based in the same building as the CoG, is contributing a bunch of its Daydream.VR smartphone headsets to hackathon attendees, as well as mentors to get your project up and running. Other sponsors include 1st Playable Productions and Vicarious Visions, game studios both located in the Troy area. And to draw in the hardcore game programmers, a concurrent Ludum Dare game jam will be run by the Tech Valley Game Space, with interaction and collaboration between the AR/VR hackers and the programmers encouraged. Teams will compete for $1000 in prizes and other giveaways.

This sounds like it’s going to be an amazing chance to hack, to collaborate, and to make connections in the growing AR/VR field. And did we mention the food? There was a ton of it last time, so much they were begging us to take it home on Sunday night. Go, hack, create, mingle, and eat. TVCoG knows how to hackathon, and you won’t be disappointed.

Thanks to [Duncan Crary] for the heads up on this.

Take The Long Road To A Precise Laser PCB Exposer

April 6, 2016 by Gerrit Coetzee 23 Comments

According to [diyouware], inside of every HD-DVD player is a gem of laser engineering with the designation of PHR-803T, and it’s just begging to be converted into a PCB exposer. Following along similar hacks which tore the laser diode out of Blu-ray players to expose PCBs, they wanted to use the whole PHR-803T unit without disassembling it, and to try to enable all of its unique features.

They envisioned something simple like a scanner for their machine. Just place the PCB on top of a glass sheet, close the lid, and click print. Unfortunately, moving the laser itself just caused too much vibration. So they switched to an inverted delta robot and named it TwinTeeth. In this design, the laser would stay still and the PCB would move.

What follows next is a seriously impressive journey in reverse engineering and design. The PHR-803T had no data sheet, but a ton of features. For example, it can autofocus, and has three different laser diodes. So many interesting problems were found and solved. For example, the halo from the laser caused the surrounding photoresist to cure. They solved it by adding a glass plate with a UV filtering film on it. Only the most focused point of the laser could punch through.

Another adventure was the autofocus. They wanted to autofocus on all four corners of the board. The PHR-803T was designed to read HD-DVDs so can focus a beam to far below 0.01 mm. They got autofocus working with the UV laser, but couldn’t use it on the PCB without curing the photoresist. So they put a piece of aluminum foil at a known level to start. Then they realized they could use the red or infrared diodes to focus instead. Now they can level the PCB in software, and focus the diode without curing the photoresist.

In the end they have an inverted-delta mini PCB factory. It can produce boards around the size of an Arduino shield with a resolution of 600 DPI. Their machine also has attachments for drilling and solder paste dispensing. Check out the video of it in action.
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