Spinning Up A Water Cooled 3D Printed Stirling Engine

March 31, 2021 by Tom Nardi 7 Comments

The Stirling external combustion engine has fascinated gear heads since its inception, and while the technology has never enjoyed widespread commercialization, there’s a vibrant community of tinkerers who build and test their own takes on the idea. [Leo Fernekes] has been working on a small Stirling engine made from 3D printed parts and common hardware components, and in his latest video he walks viewers through the design and testing process.

We’ve seen Stirling engines with 3D printed parts before, but in most cases, they are just structural components. This time, [Leo] really wanted to push what could be done with plastic parts, so everything from the water jacket for the cold side of the cylinder to the gears and connecting rods of the rhombic drive has been printed. Beyond the bearings and rods, the most notable non-printed component is the stainless steel spice shaker that’s being used as the cylinder.

The piston is made of constrained steel wool.

Mating the hot metal cylinder to the 3D printed parts naturally introduced some problems. The solution [Leo] came up with was to design a toothed collar to hold the cylinder, which reduces the surface area that’s in direct contact. He then used a piece of empty SMD component feed tape as a insulator between the two components, and covered the whole joint in high-temperature silicone.

Like many homebrew Stirling engines, this one isn’t perfect. It vibrates too much, some of the internal components have a tendency to melt during extended runs, and in general, it needs some fine tuning. But it runs, and in the end, that’s really the most important thing with a project like this. Improvements will come with time, especially once [Leo] finishes building the dynamometer he hopes will give him some solid data on how the engine’s overall performance is impacted as he makes changes.

If you’ve got a glass test tube laying around, putting together a basic Stirling engine demonstration is probably a lot easier than you might think. Commercial kits are also available if you’re looking for something more substantial, but even those can benefit from some aftermarket modifications. With a little effort, you’ll have a power plant ready for the surface of Mars in no time.

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An Ancient 8 Inch Floppy, With A PC

March 27, 2021 by Jenny List 41 Comments

Most of us may have gratefully abandoned the floppy disk a decade or more since, but even today many PCs and their operating systems retain the ability to deal with these data storage relics. The PC was widely fitted with either 5.25″ or 3.5″ disk drives, but other formats such as the older 8″ discs were not a fixture in the 16-bit desktop computing world. It’s something [Jozef Bogin] has taken aim at, with his exploits in connecting a variety of 8″ drives to a PC.

In the early 1970s there were a variety of different 8″ drive standards that weren’t all entirely compatible, but a de facto standard emerged as clones of the Shuggart drives used by IBM. It’s a modified version of this interface that can be found in a PC floppy controller. While there is enough electrical compatibility to connect the two there remains a variety of connectors used on the drives. There are also a wide range of power supplies, with drives requiring 5, 12, and 24 volts, and some of them even requiring AC mains with different versions for 50Hz and 60Hz mains frequencies.

With an 8″ drive hooked up to a PC, how might DOS, or even older Windows versions, interface with it? To that end he’s created a piece of software called 8format, which not only allows 8″ disks to be formatted for the PC, but also provides a driver that replaces the BIOS floppy settings for these drives. This doesn’t work for imaging disks from other older platforms, but he provides pointers to more capable floppy controllers for that.

If these drives interest you, there’s more to be gleaned from a tale of interfacing them with 8-bit retrocomputers.

A Lockdown Brightened By A Library Of Vintage Usborne Books

March 22, 2021 by Jenny List 33 Comments

Lockdown is boring. No, let’s emphasize that, lockdown is really boring. Walking for exercise is much less fun than it was last year because it’s a wet and muddy February, and with nowhere open, a rare trip out to a McDonalds drive-through becomes a major outing. Stuck inside for the duration we turn our eyes to some of the older ways to wile away the time. Books. Remember them? In doing that I found that the friend whose house I’m living in has the whole library of Usborne children’s computer and technology books from the 1980s. Suddenly a rainy day doesn’t matter, because we’re in a cheerful world of cartoon robots and computer parts!

When Kids Learned Machine Code

A comprehensive selection to get one's teeth into. — A comprehensive selection to get one’s teeth into.

If this leaves you none the wiser, it’s worth explaining that during the 1980s home computer boom there was no Internet handily placed for finding out how your new toy worked. Instead you had to read books and hoard the scraps of information they contained. Publishers responded to this new world of technology with enthusiasm, and the British children’s publisher Usborne did so in their characteristic entertaining and informative style. For probably the only time in history, children were presented with mainstream books telling them how to write machine code and interface directly to microprocessors, and those among them who probably now read Hackaday took to them with glee. They remain something of a cult object among retrocomputing enthusiasts, and fortunately a selection of them are available for download. Usborne are still very much in business producing up-to-date books educating today’s children, and to promote some of their more recent titles for the Raspberry Pi they’ve released them in electronic form. Continue reading “A Lockdown Brightened By A Library Of Vintage Usborne Books” →

Reproducing A Reproducer: Servicing A Cylinder Phonograph In The Year 2021

March 20, 2021 by Kristina Panos 11 Comments

[Jan Derogee] pulled out his phonograph the other day to hear the 100+ year old wax cylinder warble of “It’s a Long Way to Tipperary”, but couldn’t locate the reproducer — this is the small circular bit that holds the stylus and transfers the groove-driven vibrations to the center of a thin diaphragm, which vibrates into the sound horn. It’s easily the most important part of a cylinder phonograph. What do you do when you lose your reproducer? You could search ebay for a replacement, but that wouldn’t be nearly as fun as reproducing your reproducer yourself.

Traditionally, diaphragms were made from mica or celluloid, and the Edison disk phonograph used seven layers of shellac-soaked rice paper. Reproducers typically have a Dagwood sandwich of gaskets surrounding the membrane, but they don’t have to be so convoluted to work — a single strong membrane will do just fine. Just ask [Jan], who made a new reproducer with a 3D-printed case, a hand-pulled glass stylus, and a disposable aluminum foil pan for the diaphragm.

It’s difficult for us to say which part looks more fun — stretching the glass shard over a gas kitchen stove with the flame focused by a stack of wrench sockets, or cutting up a bicycle inner tube and using a car jack to press the aluminum into shape against a 3D-printed mold. The whole video is awesome and you can check it out after the break.

As [Jan] notes in the video and on the project site, the glass stylus should really be made from borosilicate because it’s harder than regular soda lime glass (that’s why they often make vaccine vials out of it). Regular glass will work and takes much less time and gas to reach the pull-able stage, so that’s what [Jan] used in the video, but it will wear out much more quickly. Fortunately, this was a temporary solution, because as soon as [Jan] made a replacement, the missing reproducer showed up.

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How To Cobble A Wobble Disk Roaster Together

March 14, 2021 by Kristina Panos 9 Comments

As with anything else, once your knowledge of coffee expands, the more attractive it becomes to control as much of the process as possible. Buying whole beans and grinding them at home is one thing, but you’re not a real coffee geek unless you’re buying big bags of green beans and roasting them yourself in small batches.

[Larry Cotton] has made an even more portable version of the wobble disk roaster we saw last summer. Beneath the housing made of aluminium flashing is the guts of a $15 Harbor Freight heat gun pointing upward at a metal strainer. A large metal disk mounted at a 45-degree angle to the spinning axis tosses and turns the beans as they get blasted with heat from below. [Larry] used a 12 VDC motor to run the wobble disk, and an an adapter to change the heat gun from 120 VAC to 12 VDC. This baby roasts 1½ cups of beans to city plus (medium) level in 12-15 minutes. Grab a cup of coffee and check it out after the break.

Roasting beans isn’t rocket science. Even so, there are some things you would benefit from knowing first, so here’s our own [Elliot Williams] on the subject of building DIY roasters.

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It’s Not A Computer If It Doesn’t Have A Cartridge Slot

March 13, 2021 by Jenny List 25 Comments

For viewers of sci-fi TV and films from the 1960s onwards, the miniaturisation of computer hardware has been something of a disappointment. Yes, it’s amazing that we can get 1.21 Jigabytes onto a memory card that fits comfortably under a postage stamp, but we were promised a different future. One of satisfyingly chunky data modules that activated everything from starships to handheld data recorders to malevolent rogue supercomputers, and one that has so far only materialised in the form of cartridges for game consoles.

Our colleague [Tom Nardi] has the solution for his cyberdeck though, in the form of 3D-printed cartridge shells that hide regular USB hardware and mate with a concealed USB socket in the slot. So far he’s designed cartridges for Flash drives, WiFi and Bluetooth adapters, a Wemos D1 Mini, a receptacle, and a parametric reference design.

It’s a bit of pleasing retro fun, but behind it all could be a surprisingly practical and useful expansion system. Each cartridge contains enough space for a lot of extra electronics, so it’s almost the ideal format for building a USB-driven project inside. Best of all since the interface is USB, it still works with conventional USB plugs and sockets. We like the idea, and it’s one that would be a good addition to any cyberdeck project.

We’re far more used to seeing home-made cartridges on game consoles.

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RIP Lou Ottens, Developer Of The Compact Cassette And More

March 12, 2021 by Jenny List 30 Comments

It’s with sadness that we note the passing at the age of 94 of the long-time Phillips engineer Lou Ottens, who is best known as the originator of the Compact Cassette audio tape format that was so ubiquitous through the later decades of the 20th century. Whether you remember cassettes as the format for 8-bit software, for teenage mixtapes on a Walkman, they began life at his hands in the early 1960s at the Phillips factory in Hasselt, Belgium.

Through a long career with the Dutch electronics company, he was responsible either directly or in part for a string of consumer electronic devices that we would see as ubiquitous over the latter half of the century. Before the cassette he had developed the company’s first portable reel-to-reel tape recorder, and in the 1970s while technical director of their audio division he led the team that would develop the CD. He was reported as saying that his great regret was not beating Sony to the development of the miniature cassette player that would be sold as the Walkman, but we’d suggest that the Walkman would not have been possible without the cassette in the first place.

So next time you handle a cassette tape, spare a thought for Lou, an audio engineer whose work permeated so much of the last half-century.

Thanks [Carl] for the tip.

Images: Lou Ottens by Jordi Huisman CC BY-SA 4.0 and “An early Phillips cassette recorder” by mib18 CC BY-SA 3.0