Boss Byproducts: Fordites Are Pieces Of American History

August 28, 2024 by Kristina Panos 17 Comments

Some of the neatest products are made from the byproducts of other industries. Take petroleum jelly, for example. Its inventor, Robert Chesebrough, a chemist from New York, came upon his idea while visiting the oil fields of Titusville, Pennsylvania in 1859. It took him ten years to perfect his formula, but the product has been a household staple ever since. Chesebrough so believed in Vaseline that he ingested a spoonful of it every day, and attributed his 96-year longevity to doing so.

Well, some byproducts can simply be beautiful, or at least interesting. On that note, welcome to a new series called Boss Byproducts. We recently ran an article about a laser-engraved painting technique that is similar to the production of Fordite. I had never heard of Fordite, but as soon as I found out what it was, I had to have some. So, here we go!

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RC Car Gets Force Feedback Steering

August 6, 2024 by Bryan Cockfield 8 Comments

Remote-controlled cars can get incredibly fast and complex (and expensive) the farther into the hobby you get. So much so that a lot of things that are missing from the experience of driving a real car start to make a meaningful impact. [Indeterminate Design] has a few cars like this which are so fast that it becomes difficult to react to their behavior fast enough through sight alone. To help solve this problem and bridge the gap between the experience of driving a real car and an RC one, he’s added force feedback steering to the car’s remote control.

The first thing to tackle is the data throughput required to get a system like this working wirelessly. Relying heavily on the two cores in each of a pair of ESP32s, along with a long-range, high-speed wireless communications protocol called ESP-NOW, enough data from the car can be sent to make this possible but it does rely on precise timing to avoid jitter in the steering wheel. Some filtering is required as well, but with the small size of everything in this build it’s also a challenge not to filter out all of the important high-frequency forces. With the code written, [Indeterminate Design] turned to the 3D printer to build the prototype controller with built-in motors to provide the haptic feedback.

The other half of the project involves sensing the forces in the RC car which will then get sent back to the remote. After experimenting with a mathematical model to avoid having to source expensive parts and finding himself at a deadend with that method, eventually a bi-directional load cell was placed inside the steering mechanism which solved this problem. With all of these pieces working together, [Indeterminate Design] has a working force feedback steering mechanism which allows him to feel bumps, understeer, and other sensations, especially while doing things like drifting or driving through grass, that would be otherwise unavailable to drivers of RC cars. The only thing we could think of to bring this even more into realistic simulation territory would be to add something like a first-person view like high-speed drones often have.

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Car Becomes A Massive Bubble Machine

July 25, 2024 by Lewin Day 13 Comments

You’ve probably seen street performers or family members making giant bubbles at some point in your life. But what if you could go ever bigger…even approaching a bubble of infinite length? That’s precisely what [Engineezy] tried to do.

The common technique behind blowing big bubbles involves attaching a thick rope to two sticks, then dipping the sticks in bubble fluid. The two sticks can then be spread apart to act as a big triangular bubble wand to create massive bubbles.

So the idea here to create a giant bubble-blowing frame using the same technique, continually feed it with bubble fluid, and stick it on top of a car. Spread the wings of the bubble wand, and watch the bubble grow. Oh, and this setup uses special bubble fluid—made by mixing soap, water, and veterinary J-Lube in specific ratios. Feeding the car-mounted wand with fluid was achieved by tubing delivering a continuous flow. Early small-scale attempts created wild 25 foot bubbles, while the car version made one over 50 feet long. Not infinite, but very cool.

As it turns out, the science of bubbles is deep and interesting.

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Toyota Heater Switches Learn New Tricks

July 5, 2024 by Tom Nardi 32 Comments

The look, the feel, the sound — there are few things more satisfying in this world than a nice switch. If you’re putting together a device that you plan on using frequently, outfitting it with high-quality switches is one of those things that’s worth the extra cost and effort.

So we understand completely why [STR-Alorman] went to such great lengths to get the aftermarket seat heaters he purchased working with the gorgeous switches Toyota used in the 2006 4Runner. That might not sound like the kind of thing that would involve reverse engineering hardware, creating a custom PCB, or writing a bit of code to tie it all together. But of course, when working on even a halfway modern automobile, it seems nothing is ever easy.

The process started with opening up the original Toyota switches and figuring out how they work. The six-pin units have a lot going on internally, with a toggle, a rheostat, and multiple lights packed into each one. Toyota has some pretty good documentation, but it still took some practical testing to distill it down into something a bit more manageable. The resulting KiCad symbol for the switch helps explain what’s happening inside, and [STR-Alorman] has provided a chart that attributes each detent on the knob with the measured resistance.

But understanding how the switches worked was only half the battle. The aftermarket seat heaters were only designed to work with simple toggles, so [STR-Alorman] had to develop a controller that could interface with the Toyota switches and convince the heaters to produce the desired result. The custom PCB hosts a Teensy 3.2 that reads the information from both the left and right seat switches, and uses that to control a pair of beefy MOSFETs. An interesting note here is the use of very slow pulse-width modulation (PWM) used to flip the state of the MOSFET due to the thermal inertia of the heater modules.

We love the effort [STR-Alorman] put into documenting this project, going as far as providing the Toyota part numbers for the switches and the appropriate center-console panel with the appropriate openings to accept them. It’s an excellent resource if you happen to own a 4Runner from this era, and a fascinating read for the rest of us.

Nine men of various ages and ethnicities stand in a very clean laboratory space. A number of large white cabinets with displays are on the left behind some white boards and there are wireless charging coils on a dark tablecloth in the foreground. In the back of the lab is a white Porsche Taycan.

Polyphase Wireless EV Fast Charging Moves Forward

June 21, 2024 by Navarre Bartz 80 Comments

While EV charging isn’t that tedious with a cable, for quick trips, being able to just park and have your car automatically charge would be more convenient. Researchers from Oak Ridge National Lab (ORNL) and VW have moved high-speed wireless EV charging one step closer to reality.

We’ve seen fast wireless EV chargers before, but what sets this system apart is the coil size (~0.2 m² vs 2.0 m²) and the fact it was demonstrated on a functioning EV where previous attempts have been on the bench. According to the researchers, this was the first wireless transfer to a light duty vehicle at 270 kW. Industry standards currently only cover systems up to 20 kW.

The system uses a pair of polyphase electromagnetic coupling coils about 50 cm (19″) wide to transfer the power over a gap of approximately 13 cm (5″). Efficiency is stated at 95%, and that 270 kW would get most EVs capable of those charge rates a 50% bump in charge over ten minutes (assuming you’re in the lower part of your battery capacity where full speeds are available).

We’ve seen some in-road prototypes of wireless charging as well as some other interesting en route chargers like pantographs and slot car roads. We’ve got you covered if you’re wondering what the deal is with all those different plugs that EVs have too.

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Open Source Your Air Ride Suspension

June 19, 2024 by Navarre Bartz 8 Comments

Air ride suspensions have several advantages over typical arrangements, but retrofitting a system to a vehicle that didn’t come with it can get pricey fast, especially if you want to go beyond the basics. The Open Source Air Suspension Management Controller aims to give people a fully customizable system without the expense or limitations of commercial units.

The project started as an upgrade to a basic commercial system, so it assumes that you’re bringing your own “bags, tank, compressor, tubing and fittings.” The current board uses an Arduino Nano, but the next revision based on the ESP32 will allow for a wider feature set.

With a Bluetooth connection and Android app, you can control your ride height from a phone or integrated Android head unit. Currently, the app shows the pressure readings from all four corners and has controls for increasing or decreasing the pressure or airing all the way up or down to a given set point.

Want to know how air suspensions work? How about this LEGO model? If you want a suspension with active tuning for your bike, how about this Arduino-powered mod?

From Nissan ICE Pickup To BEV With Nissan Leaf Heart

June 11, 2024 by Maya Posch 9 Comments

Last year [Jimmy] got a request from a customer ([Dave]) to help convert a 1998 Nissan Frontier pickup into an electric drive vehicle, with a crashed 2019 Nissan Leaf providing the battery and electric motor for the conversion. He has documented the months-long journey with plenty of photos, as well as a series of videos over at the [EVSwap Conversions] YouTube channel. While the idea sounds easy enough, there’s a lot more to it than swapping out the ICE with an electric motor and sticking some batteries to the bottom of the car somewhere with double-sided tape. The pickup truck got effectively stripped down and gutted, before the 110 kW (150 HP) motor got installed using an adapter plate.

The donor Leaf’s battery pack came in at a decently sized 40 kWh, which should give the converted Nissan Frontier BEV a range of easily 100 miles. This pack was split up into two packs, which got put into a custom aluminium battery box, each mounted on one side of the driveshaft. The charging port got installed on the front of the car, next to the logo, discreetly behind a panel. The front of the car had much of the openings that were needed for the ICE’s radiator sealed up for reduced air friction, along with the new low-friction tires that got installed. Although this converted car still has a radiator, it only needs to assisting cooling the motor stack (including inverter and charger) when driving slowly or charging, making it far less demanding and thus allows for a more sleek front.

As a bonus, the car still has the manual 5-gear shift, just without a clutch, and the pickup bed can now also tilt, albeit with hydraulics (so far). Considering that it started with a decent 1998 pickup and totaled Nissan Leaf, this is among the cleanest conversions we have seen, not to mention a good use of a crashed BEV.

Thanks to [JohnU] for the tip.

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