A Professional Spot Welder Made Out Of A Microwave Transformer

September 21, 2014 by James Hobson 39 Comments

Spot welders are one of the very few pieces of metal working equipment that are actually very much cheaper to build yourself than to buy commercially. In fact, between salvaging a transformer out of an old microwave and buying some of the other components, it’s doable for under $100USD in most cases.

We’ve shared this hack quite a few times before, but [Albert van Dalen] has really taken the cake on creating a very detailed and extensive guide to not only building his, but how to properly use it for various purposes.

[Albert] designed it in a way that allows it to be configured in both opposed and series electrode positions which means besides being able to spot weld sheet metal together, you can also spot weld battery tabs while on cells!

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Open Source Hackable Robot

September 20, 2014 by Bryan Cockfield 15 Comments

The world of robots is an interesting place, and it’s an even better place for children to get started in electronics. To that end, [Richard Albritton] has created a low-cost, open source robotics platform called the Hack-E-Bot specifically tailored to make it as easy as possible to get started.

The goals for the robot kit were to spark curiosity for electronics and programming, to be easy to assemble and program, to be scalable, and to be as easy on the wallet as possible. This was accomplished by using the familiar Arduino microcontroller on an intuitive platform. The robot uses an ultrasonic rangefinder to navigate as well, and can support a wide range of other sensors. The kit comes in at just under $50, making it a great option for an entry-level robot.

The project is currently seeking crowd funding and [Richard] is also seeking educators to get involved. Currently the only kits available are at fairs and other conventions but they should be able to start producing them in greater quantities in the future. The Arduino libraries are a work in progress but they are available on the project site, as well as several instructional videos and other information about the project.

THP Semifinalist: Cheap Satellite Transponder

September 20, 2014 by Brian Benchoff 7 Comments

In 2016, a communications satellite will be launched into geostationary orbit somewhere over the middle east. Normally, this is fairly ordinary occurrence. This satellite, however, will be carrying two amateur radio transponders for hams all across europe, africa, the middle east, and India. [2FTG] is building a satellite transponder to talk to this satellite, and he’s doing it with junk sitting around his workbench.

The uplink frequency for this satellite will be in the neighborhood of 2.4 GHz, and [2FTG] needed a way to deal with the out of band interference in this part of the spectrum. The easy and cheap way to do this is with filters made for the WiFi band. Instead, [2FTG] had a few cavity filters in his junk box and decided to go that route. It meant he had to retune the filters, a process that should be annoyingly hard. [2FTG] did it in thirty minutes.

Antennas are another matter, but since [2FTG] has a supply of metal coffee cans, this part of the build was just a matter of soldering a bit of wire to an SMA connector, drilling a hole (using a log as a drill stop, no less), and soldering the connector to the can.

The project featured in this post is a quarterfinalist in The Hackaday Prize.

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Low-Level Computing With Entry-Level Difficulty: DUO Light

September 20, 2014 by Mike Szczys 27 Comments

The hardware can’t get much simpler. The DUO Light uses an ATmega328 (commonly found on Arduino boards) along with an external SRAM chip to provide a low-level computer programming experience that will suit those new to programming and some more experienced tinkerers.

At the time of writing the modest Kickstarter goal of $1100 was just $18 shy of success. We’d wager that this is partly due to the availability of so much support material on [Jack’s] website. (fyi- a lot of the links on that page are zip files)

The SD card slot accepts a FAT16 card with byte code for the programs. The available Psuedo C compiler, and assembler let you pick your poison, or you can simply dig into the byte code directly. We didn’t see a schematic, but the firmware and BOM are both available. You should be able to easily figure out connections from those.

We’ve been a fan of [Jack’s] work for quite some time. His TTL computer and 16-core ATmega-based offerings are sure to delight, even if you remember seeing them go by the first time. This isn’t his first stab at educational models either. Though we still found his logic chip computer a bit daunting.

NYC Maker Faire: The Logistics Of Manufacturing Pentagons

September 20, 2014 by Brian Benchoff 3 Comments

Most of the Maker Faire attendees have spent weeks or months putting together their projects. [Matt] is doing things a little differently. He brought two thousand boards, each containing twelve pentagon PCBs with individually addressable LEDs mounted in the center. This weekend, he, his team, and anyone else who can wield a soldering iron will be assembling these pentagon panels into a gigantic glowing crystal.

Last year, [Matt] put together a Kickstarter for Blinkytape, a WS2812 LED strip with an Arduino on one end of the strip to generate patterns of colors. This year, [Matt] is moving into three dimensions with a system of pentagons with a single RGB LED mounted in the center. The pentagons can be soldered together into a regular polyhedra or a convoluted wall of LEDs that form a geometric crystal pattern of blinkyness. The Kickstarter for the BlinkyTile should be up before the faire is over.

[Matt] has a few tips for anyone wanting to run their own Kickstarter: don’t have a lot of SKUs. [Matt] only has to keep track of a single panel of twelve pentagons. Compare this to other failed Kickstarters with dozens of options, several colors, and a few stretch goals, and you quickly see why many, many Kickstarters fail. [Matt] is just selling one thing.

Munich: Help Plan Hackaday’s First European Event

September 20, 2014 by Mike Szczys 9 Comments

On Thursday, November 13th we’ve rented a huge hall in Munich, Germany and plan to host a hacking event followed by a celebration.

You need to take the day off of work and join us. Better yet, convince your boss that this is professional development and that attending is good for the company!

We’re not taking the space shuttle across the pond, this illustration reflects the connection with The Hackaday Prize. This trip will mark the end of the contest and the unveiling of the Grand Prize winner.

What do you want to hack?

The big question we have right now, is what kind of hands-on hardware hacking do you want to do? We published a page over on Hackaday.io to discuss the possibilities. Let your imagination run wild and we’ll do our best to make it all happen. We know from James’ hackerspace tour last year that there are a ton of Hackaday community members within reasonable travel distance from Munich. Here’s our chance to get everyone together for an Epic day of building and night of partying.

PSP Lithium Hack Could Be Called The Franken-Cell

September 20, 2014 by Mike Szczys 19 Comments

You assume that you’ll be able to get parts forever… after all: The Internet. But what if you can’t justify paying the price for them? [Cristi C.] was in this situation, not wanting to fork over $30+ for a replacement PSP battery. The handheld gaming rig itself was just discontinued this year but supposedly the batteries have been out of production for some time. What you see above is the controller board from an original battery, with the cell from a camera battery.

The key is protection. The chemistry in Lithium cells of several types brings a working voltage of around 3.7V. Swapping the cells — even if they are different capacities — should work as protection circuits generally measure current, voltage, and sometimes temperature as they charge in order to know when the cell is full. With this in mind [Christi] cracked open a used Canon NB-6L type battery and grabbed the prismatic cell as a replacement for the pouch cell in the Sony S110 case (PDF). The Canon cell is enclosed in a metal case and is just a bit smaller than the pouch was. This means with careful work it fit back inside the original plastic enclosure.

On a somewhat related note, be careful when sourcing brand-x batteries. Some manufacturers implement checks for OEM equipment but there are ways around that.