A closeup of the faulty section of the dial - you can spot the plastic rivets that broke off

The Tale Of Two Broken Flukes

March 1, 2023 by 11 Comments

Some repairs happen as if by pure luck, and [Sebastian] shows us one such repair on Hackaday.io. He found two Fluke 175 meters being sold on eBay, with one having a mere beeper issue, and another having a “strange error”. Now, theoretically, swapping beepers around would give you one working meter and a kit of spare parts – but this is Fluke we’re talking about, and [Sebastian] wasn’t satisfied leaving it there.

First, he deduced that the beeper issue could be fixed by repositioning the piezo disk – and indeed, that brought the meter number one to working order. This left the mysterious error – the meter would only power up in certain rotations of the dial, and would misbehave, at that. Disassembly cleared things up – the dial mechanics failed, in that a half of the metal contacts came detached after all the plastic rivets holding the metal piece in place mysteriously vanished. The mechanics were indeed a bit intricate, and our hacker hoped to buy a replacement, but seeing the replacement switch prices in three-digit range, out came the epoxy tube.

An epoxy fix left overnight netted him two perfectly working Fluke meters, and while we don’t know what the listing price was for these, such a story might make you feel like taking your chances with a broken Fluke, too. The tale does end with a word of caution from [Sebastian], though – apparently, cleaning the meters took longer than the repairs themselves. Nevertheless, this kind of repair is a hobbyist’s dream – sometimes, you have to design a whole new case for your meter if as much as a wire breaks, or painstakingly replace a COB with a TQFP chip.

Self-Destructing USB Drive Releases The Magic Smoke

March 1, 2023 by 52 Comments

There were some that doubted the day would ever come, but we’re happy to report that the ambitious self-destructing USB drive that security researcher [Walker] has been working on for the last 6+ months has finally stopped working. Which in this case, is a good thing.

Readers may recall that the goal of the Ovrdrive project was to create a standard-looking flash drive that didn’t just hide or erase its contents when accessed by an unauthorized user, but actively damaged itself to try and prevent any forensic recovery of the data in question. To achieve this, [Walker] built a voltage doubler circuit into the drive that produces 10 volts from the nominal 5 VDC coming from the USB port. At the command of an onboard microcontroller, that 10 V is connected to the circuit’s 3.3 V rail to set off the fireworks.

Early attempts only corrupted some of the data, so [Walker] added some more capacitance to the circuit to build up more of a charge. With the revised circuit the USB controller IC visibly popped, but even after it was replaced, the NAND flash was still unresponsive. Sounds pretty dead to us.

Too user friendly, needs more buttons

Unfortunately, there’s still at least one issue that’s holding back the design. As we mentioned previously, [Walker] was having trouble getting the computer to actually acknowledge his homebrew drive had any free space available. It turns out that the SM3257EN USB controller IC he’s using needs to be initialized by some poorly documented Windows XP software, which might not be such a big deal if the goal was just to build one of them, but could obviously be a hindrance when going into production.

He hopes further reverse engineering will allow him to determine which commands the XP software is giving to the IC so that he can duplicate them in a less ancient environment. Sounds like a job for Wireshark to us — with any luck he should be able to capture the commands being sent to the hardware and replay them.

While we can understand some readers may have lingering doubts about the drive’s spit-detection authentication system, it’s clear [Walker] has made some incredible progress here. This project demonstrates that not only can an individual spin up their own sold state storage, but that should they ever need to, they can also destroy it in an instant.

A Thoroughly Modern Serial Terminal

March 1, 2023 by 16 Comments

The humble desktop serial terminal may have long disappeared from the world of corporate IT, but there are still plenty of moments when professionals and enthusiasts alike need to hook up to a serial port. Many of us use a serial port on our laptops or other mobile devices, but [Neil Crawforth] has gone one better than that with the VT2040. It’s an old-style serial terminal in a super-handy portable format, and as one might guess from the name, it has an RP2040 microcontroller at its heart.

Attached to the chip is a rather nice keyboard, and an ILI9488 480×320 LCD display. The software is modular, providing a handy set of re-usable libraries for the different functions including a PIO-based serial port. His main application seems to be talking to an ESP8266, but we’re guessing with a MAX232 or other level shifter chip it could drive a more traditional port. Everything can be found in the project’s GitHub repository, allowing anyone to join the fun.

As long-time readers will know, we’ve been partial to a few serial terminals in the past. Particularly beloved is this extremely retro model with vintage dot matrix LEDs.

The Die Is Cast!

March 1, 2023 by 31 Comments

We all know the basics of how metal casting works, a metal is heated up to melting point and the resulting liquid metal is poured into a mold. When the metal sets, it assumes the shape of the mold. It’s a straightforward way to reliably replicate a metal item many times over, and the basics are the same whether the metal is a low-temperature alloy in a silicone mould or a crucible of molten steel poured into a sand mould.

The mould is black sand in a cast iron box, and the pattern piece is half submerged in it
A sand mould being formed around a pattern. Lukas Stavek, CC BY-SA 3.0 .

What we all understood as casting in our conversation was sand casting. Sand is packed around a pattern of the piece to be cast, and then the pattern is removed leaving a cavity in its shape which becomes the mould. There are refinements to this process and the mould is frequently formed in two halves, but it’s something that’s even practical to do in a hackerspace level setting.

A refinement of sand casting is so-called lost-wax casting, in which a hollow wax model of the piece to be cast is packed around with sand, and when the metal is poured onto the top of it the wax melts and the wax is melted out before pouring the metal in to take its place. A variation on this appears here from time to time, so-called lost-PLA casting, where the wax model is replaced with a PLA 3D print.

Injection Molding For Metals

Diagram of a die casting machine
A die casting machine. Ahmed elbhje, Public domain.

Where our confusion crept in was with die casting. We could recognise a die-cast piece, but just what is die-casting, and how is a die-casting made? The answer there lies in mass-production, because a snag with sand casting is that  a sand mould can be labour intensive to produce. Much better to come up with a quick-turnaround process that re-uses the same mould over and over, and save all that time!

Enter the die-casting, to metalwork what injection moulding is to polymers. The die is a mould made out of metal, usually with liquid cooling, and the casting is done not by pouring but by forcing the molten metal into the mould under pressure. The whole process becomes much quicker, meaning that it can become a piece of process machinery spitting out castings rather than a labour-intensive individual task. The metals used for die-casting are the lower temperature ones such as aluminium, zinc, and their alloys, but  you will find die-castings in all conceivable places.

It’s obvious that Hackaday editors are not experienced foundrymen even if some of us grew up around metalwork, but we know that among our readers lie genuine experts in all sorts of fields. If that’s you and you operate a die-casting machine, please take a moment to tell us about it, we really would like to know more!

Header: Constantin Meunier, Public domain.

Morse Code Clock For Training Hams

March 1, 2023 by 13 Comments

It might seem antiquated, but Morse code still has a number of advantages compared to other modes of communication, especially over radio waves. It’s low bandwidth compared to voice or even text, and can be discerned against background noise even at extremely low signal strengths. Not every regulatory agency requires amateur operators to learn Morse any more, but for those that do it can be a challenge, so [Cristiano Monteiro] built this clock to help get some practice.

The project is based around his favorite microcontroller, the PIC16F1827, and uses a DS1307 to keep track of time. A single RGB LED at the top of the project enclosure flashes the codes for hours in blue and minutes in red at the beginning of every minute, and in between flashes green for each second.

Another design goal of this build was to have it operate with as little power as possible, so with a TP4056 control board, single lithium 18650 battery, and some code optimization, [Cristiano] believes he can get around 60 days of operation between charges.

For a project to help an aspiring radio operator learn Morse, a simple build like this can go a long way. For anyone else looking to build something similar we’d note that the DS1307 has a tendency to drift fairly quickly, and something like a DS3231 or even this similar Morse code clock which uses NTP would go a long way to keeping more accurate time.

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FOSDEM 2023: An Open-Source Conference, Literally

March 1, 2023 by 6 Comments

Every year, on the first weekend of February, a certain Brussels university campus livens up. There, you will find enthusiasts of open-source software and hardware alike, arriving from different corners of the world to meet up, talk, and listen. The reason they all meet there is the conference called FOSDEM, a long-standing open-source software conference which has been happening in Belgium since 2000. I’d like to tell you about FOSDEM because, when it comes to conferences, FOSDEM is one of a kind.

FOSDEM is organized in alignment with open-source principles, which is to say, it reminds me of an open-source project itself. The conference is volunteer-driven, with a core of staff responsible for crucial tasks – yet, everyone can and is encouraged to contribute. Just like a large open-source effort, it’s supported by university and company contributions, but there’s no admission fees for participants – for a conference, this means you don’t have to buy a ticket to attend. Last but definitely not least, what makes FOSDEM shine is the community that it creates.

FOSDEM’s focus is open software – yet, for hackers of the hardware world, you will find a strong hardware component to participate in, since a great number of FOSDEM visitors are either interested in hardware, or even develop hardware-related things day-to-day. It’s not just that our hardware can’t live without software, and vice-versa – here, you will meet plenty of pure software, a decent amount of pure hardware, and a lot of places where the two worlds are hard to distinguish. All in all, FOSDEM is no doubt part of hacker culture in Europe, and today, I will tell you about my experience of FOSDEM 2023. Continue reading “FOSDEM 2023: An Open-Source Conference, Literally” →

A picture showing acupuncture needles wedged into the inside of the payment terminal

Aaron Christophel Brings DOOM To Payment Terminal

March 1, 2023 by 9 Comments

Payment terminals might feel intimidating — they’re generally manufactured with security in mind, with all manner of anti-tamper protections in place to prevent you from poking around in the hardware too much. But [Aaron Christophel] thinks that level of security isn’t aren’t always in practice however, and on his journey towards repurposing devices of all kinds, has stumbled upon just the terminal that will give up its secrets easily. The device in question is Sumup Solo terminal, a small handheld with a battery, LTE connection and a payment card slot – helping you accept card payments even if you’re on the go.

Now, this terminal has security features like the anti-tamper shield over the crucial parts of the device, leading to payment processing-related keys being erased when lifted. However, acupuncture needles, a tool firmly in [Aaron]’s arsenal, helped him reach two UART testpoints that were meant to be located under that shield, and they turned out to be all that a hacker needed to access the Linux system powering this terminal. Not just that, but the UART drops you right into the root shell, which [Aaron] dutifully explored — and after some cross–compilation and Linux tinkering, he got the terminal to, naturally, run Doom.

The video shows you even more, including the responsible disclosure process that he went through with Sumup, resulting in some patches and, we hope, even hardware improvements down the line. Now, the payment processing keys aren’t accessible from the Linux environment — however, [Aaron] notes that this doesn’t exclude attacks like changing the amount of money displayed while the customer is using such a terminal to pay.

If you’d like to take a closer look at some of the hardware tricks used in these secure devices, we did a teardown on one back in 2019 that should prove interesting.

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