Headlights. Indicators. Trunk releases. Seatbelts. Airbags. Just about any part of a car you can think of is governed by a long and complicated government regulation. It’s all about safety, ensuring that the car-buying public can trust that their vehicles won’t unduly injure or maim them in regular operation, or in the event of accident.
However, one part of the modern automobile has largely escaped regulation—namely, the humble door handle. Automakers have been free to innovate with new and wacky designs, with Tesla in particular making waves with its electronic door handles. However, after a series of deadly incidents where doors wouldn’t open, regulators are now examining if these door handles are suitable for road-going automobiles. As always, regulations are written in blood, but it raises the question—was not the danger of these complicated electronic door handles easy to foresee?
We’ve all owned something where one tiny detail drives us nuts: a blinding power LED, buttons in the wrong order, or a beep that could wake the dead. This beautifully documented project fixes exactly that kind of annoyance, only this time it’s the climate-controlled seats in a 2020 Ram 1500.
[projectsinmotion] wasn’t satisfied with adjusting seat heating and ventilation only through the truck’s touchscreen. Instead, they added real physical buttons that feel just like factory equipment. The challenge? Modern vehicles control seats through the Body Control Module (BCM) over a mix of CAN and LIN buses. To pull this off, they used an ESP32-S3 board with both CAN and LIN transceivers that sits in the middle and translates button presses into the exact messages the BCM expects.
The ESP32 also listens to the CAN bus so the new physical buttons always match whatever setting was last chosen on the touchscreen, no mismatched states, no surprises. On the mechanical side, there are 3D-printed button bezels that snap into blank switch plates that come out looking completely stock, plus a tidy enclosure for the ESP32 board itself. Wiring is fully reversible: custom adapters plug straight into the factory harness. Every pinout, every connector, and every wire color is documented with WireVis diagrams we’ve covered before, making this an easily repeatable seat-hack should you have a similar vehicle. Big thanks to [Tim] for the tip! Be sure to check out some of our other car hacks turning a mass produced item into one of a kind.
The eccentric shaft and rotor of the Mazda 12A rotary engine. (Credit: Baked Beans Garage, YouTube)
In theory, Wankel-style rotary internal combustion engines have many advantages: they ditch the cumbersome crankcase and piston design, replacing it with a simple, single-chamber design and a thick, plectrum-shaped chunk of metal that spins around inside that chamber to create virtual combustion chambers. This saves weight and maximizes performance-to-weight. Unfortunately, these types of engines are also known for burning a lot of oil and endless seal troubles, especially with early rotary Mazda engines that easily died.
Yet even 1980 versions were not without issues, a case in point is the Mazda 1st gen RX7 with a 12A rotary engine that the [Baked Beans Garage] over at YouTube got their paws on. Starting with unsuccessful attempts to make the car start, the next step was to roll the car into the morgue garage for a full teardown of the clearly deceased engine.
About 35 minutes into the video, we get to the teardown of the engine, with its parts contrasted with those of a newer revision rotary engines alongside illustrations of their functioning, making it as much an autopsy as a detailed introduction to these rotary engines. Technically, they also aren’t the original DKM-style Wankel engines, but a KKM-style engine, as designed by [Hanns-Dieter Paschke]. [Wankel] didn’t like the eccentric KKM design, as he thought it’d put too much stress on the apex seals, but ultimately the more economical KKM design was further developed.
During the autopsy of the 12A revision Mazda engine, it becomes clear that it was likely overheating that killed the engine over the course of years of abuse, along with ‘chatter’ marks of the apex seals destroying the inner chrome coating. This would have compromised compression and with it any chance of the engine running, not unlike a piston engine with badly scored cylinder walls after ingesting some metal chunks.
While the Mazda 12B and subsequent designs addressed many of the issues with the early rotary engines, its use was limited to some sports models, ending in 2012 with the RX-8. The currently produced Mazda MX-30 does use a rotary engine again in its plug-in hybrid version, but it’s only as a range extender engine that drives a generator. Looking at the internals of those Mazda rotary engines, it’s easy to see how complex they are to keep running, but you cannot help but feel a little bit of sadness that these small-but-powerful engines didn’t make much more of a splash.
To our younger readers, a car without an all-touchscreen “infotainment” system may look clunky and dated, but really, you kids don’t know what they’re missing. Buttons, knobs, and switches all offer a level of satisfying tactility and feedback that touchscreens totally lack. [Garage Tinkering] on YouTube agrees; he also doesn’t like the way his aftermarket Kenwood head unit looks in his 2004-vintage Nissan. That’s why he decided to take matters into his own hands, and hack the buttons back on.
Rather than source a vintage stereo head unit, or try and DIY one from scratch, [Garage Tinkering] has actually hidden the modern touchscreen unit behind a button panel. That button panel is actually salvaged from the stock stereo, so the looks fit the car. The stereo’s LCD gets replaced with a modern color unit, but otherwise it looks pretty stock at the end.
Adding buttons to the Kenwood is all possible thanks to steering-wheel controls. In order to make use of those, the touchscreen head unit came with a little black box that translated the button press into some kind of one-wire protocol that turned out to be an inverted and carrier-less version of the NEC protocol used in IR TV remotes. (That bit of detective work comes from [michaelb], who figured all this out for his Ford years ago, but [Garage Tinkering] is also sharing his code on GitHub.) Continue reading “Hacking Buttons Back Into The Car Stereo”→
Although most modern cars have moved to using proprietary components nearly everywhere, especially when it comes to infotainment systems, for a brief moment which peaked in the 90s and 00s most cars shipped with radios that fit in a standard size opening called a DIN slot. If you wanted a new Pioneer or Kenwood stereo it was usually a simple matter to slide the factory radio out and put your choice of aftermarket head unit in its place. [Stefan] has an E39 BMW from this era and wanted to upgrade the factory radio but use the original hardware instead of replacing it.
This isn’t just a simple stereo upgrade either. [Stefan] has gone all-out for this build which he started in 2020. Beginning with a Kotlin/Jetpack Compose Linux application to handle control input from the vehicle’s various knobs and buttons he moved on to a map application and an on-screen keyboard. From there he implemented VGA to send video to the OEM screen, and now has a fully functional system based on a Raspberry Pi. It does everything the original unit can do including playing music and showing the feed from the backup camera, plus adds plenty of new, modern features like Bluetooth.
For a certain classic car enthusiast, this build hits a sweet spot of modernizing a true classic like the E39 without removing or permanently modifying any OEM components. The amount of work that went into it is pretty staggering as well, with [Stephan] putting in over 100 hours of work just to get the video signal timing correct. We also like it because it reminds us of the flash-in-the-pan “carputer” trend from the late 00s where people in the pre-smartphone age were shoving all kinds of computing horsepower in their trunks.
As a classic car enthusiast, my passion revolves around cars with a Made in West Germany stamp somewhere on them, partially because that phrase generally implied a reputation for mechanical honesty and engineering sanity. Air-cooled Volkswagens are my favorites, and in fact I wrote about these, and my own ’72 Super Beetle, almost a decade ago. The platform is incredibly versatile and hackable, not to mention inexpensive and repairable thanks to its design as a practical, affordable car originally meant for German families in the post-war era and which eventually spread worldwide. My other soft-spot is a car that might seem almost diametrically opposed to early VWs in its design philosophy: the Mercedes 300D. While it was a luxury vehicle, expensive and overbuilt in comparison to classic Volkswagens, the engineers’ design choices ultimately earned it a reputation as one of the most reliable cars ever made.
As much as I appreciate these classics, though, there’s almost nothing that could compel me to purchase a modern vehicle from either of these brands. The core reason is that both have essentially abandoned the design philosophies that made them famous in the first place. And while it’s no longer possible to buy anything stamped Made in West Germany for obvious reasons, even a modern car with a VIN starting with a W doesn’t carry that same weight anymore. It more likely marks a vehicle destined for a lease term rather than one meant to be repaired and driven for decades, like my Beetle or my 300D.
Airbags are an incredibly important piece of automotive safety gear. They’re also terrifying—given that they’re effectively small pyrotechnic devices that are aimed directly at your face and chest. Myths have pervaded that they “kill more people than they save,” in part due a hilarious episode of The Simpsons. Despite this, they’re credited with saving tens of thousands of lives over the years by cushioning fleshy human bodies from heavy impacts and harsh decelerations.
While an airbag is generally there to help you, it can also hurt you in regular operation. The immense sound pressure generated when an airbag fires is not exactly friendly to your ears. However, engineers at Mercedes-Benz have found a neat workaround to protect your hearing from the explosive report of these safety devices. It’s a nifty hack that takes advantage of an existing feature of the human body. Let’s explore how air bags work, why they’re so darn loud, and how that can be mitigated in the event of a crash.
