Fail of the Week

133 Articles

Fail of the Week is a recurring Hackaday column that highlights the power of learning from things that simply didn’t work right. Help keep the fun rolling by writing about your past failures and sending us a link to the story — or sending in links to fail write ups you find in your Internet travels.

Fail Of The Week: EPROMs, Rats’ Nests, Tanning Lamps, And Cardboard On Fire

January 2, 2019 by 87 Comments

It all started when I bought a late-1990s synthesizer that needed a firmware upgrade. One could simply pull the ROM chip, ship it off to Yamaha for a free replacement, and swap in the new one — in 2003. Lacking a time machine, a sensible option is to buy a pre-programmed aftermarket EPROM on eBay for $10, and if you just want a single pre-flashed EPROM that’s probably the right way to go. But I wanted an adventure.

Spoiler alert: I did manage to flash a few EPROMs and the RM1X is happily running OS 1.13 and pumping out the jams. That’s not the adventure. The adventure is trying to erase UV-erasable EPROMS.

And that’s how I ended up with a small cardboard fire and a scorched tanning lamp, and why I bought a $5 LED, and why I left EPROMs out in the sun for four days. And why, in the end, I gave up and ordered a $15 EPROM eraser from China. Along the way, I learned a ton about old-school UV-erasable EPROMs, and now I have a stack of obsolete silicon that’s looking for a new project like a hammer looks for a nail — just as soon as that UV eraser arrives in the mail.

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Fail Of The Week: Hard Lessons In 3D-Printed Bushings For A Giant RC Car

December 25, 2018 by 18 Comments

Can you turn 47 pounds (21 kg) of PLA filament into a gigantic working 3D-printed RC car? No, no you can’t — at least not if you eschew proper bearings in favor of printed bushings.

That’s the hard lesson that [Joel Telling] learned with his scaled up version of the OpenRC F1 car, an RC car that can be mostly 3D-printed. The small version still has its share of non-printed parts, mainly screws and bearings. In his video series documenting the build of the upsized version, [Joel] elaborates on some of the reasons for going with printed bushings rather than bearings, which mainly boil down to hoping that the graphite lubricant powder he added would reduce friction enough to prevent the parts from welding themselves together.

The car came out looking great, and even managed to scoot about nicely for a few seconds before its predictably noisy and unhappy demise. But what was unexpected was the actual failure mode. The plastic-on-plastic running gear seemed to handle the rolling loads fine; it was the lateral force exerted on the axle by the tension of the drive belt that was too much for the printed bushing to bear.

As [Joel] rightly points out, it’s only a failure if you fail to learn something, so kudos to him for at least giving this a try. And all that PLA won’t go to waste, of course — everything else on the car worked fine, so adding one bearing should get it back on the road. He should check out our primer on bearings for a few tips on selecting the right one.

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Fail Of The Week: How Not To Electric Vehicle

December 3, 2018 by 92 Comments

If you ever doubt the potential for catastrophe that mucking about with electric vehicles can present, check out the video below. It shows what can happen to a couple of Tesla battery modules when due regard to safety precautions isn’t paid.

The video comes to us by way of [Rich], a gearhead with a thing for Teslas. He clearly knows his way around the EV world, having rebuilt a flood-soaked Tesla, and aspires to open an EV repair shop. The disaster stems from a novelty vehicle he and friend [Lee] bought as a side project. The car was apparently once a Disney prop car, used in parades with the “Mr. Toad’s Wild Ride” theme. It was powered by six 6-volt golf cart batteries, which let it maintain a stately, safe pace on a crowded parade route. [Rich] et al would have none of that, and decided to plop a pair of 444-cell Tesla modules into it. The reduced weight and increased voltage made it a real neck-snapper, but the team unwisely left any semblance of battery management out of the build.

You can guess what happened next, or spin up to the 3:00 mark in the video to watch the security camera mayhem. It’s not clear what started the fire, but the modules started cooking off batteries like roman candles. Quick action got it pushed outside to await the fire department, but the car was a total loss long before they showed up. Luckily no other cars in the garage were damaged, nor were there any injuries – not that the car didn’t try to take someone out, including putting a flaming round into [Lee]’s chest and one into the firetruck’s windshield.

[Rich] clearly knew he was literally playing with fire, and paid the price. The lesson here is to respect the power of these beefy batteries, even when you’re just fooling around.

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Fail Of The Week: Leaf Blowers Can’t Fly

November 12, 2018 by 31 Comments

Leaf blowers, the main instrument of the suburban Saturday symphony, are one of the most useful nuisances. It doesn’t take much work with a rake to convince even the most noise-averse homeowner to head to the Big Box Store to pick one up to speed lawn chores. Once you do buy one, and feel the thrust produced by these handheld banshees, you might wonder, If I let go of this thing, would it fly? 

[Peter Sripol] had that very thought and set about building a couple of leaf blower powered planes to answer the question. It’s probably not a spoiler alert to report that the answer is no, but the video below is a fun watch anyway. The surprising thing is just how close both planes came to succeeding. The first plane was a stripped-down Ryobi two-stroke leaf blower suspended from a giant wing and tail section that very nearly got off the ground. Version 1.1 gained a retractable electric boost propeller – strictly for take-offs – and lost a lot of excess weight. That plane practically leaped into the air, but alas, servo problems prevented [Peter] from shutting down the electric and flying on Ryobi alone. Even a servo fix couldn’t save the next flight, which cratered right after takeoff. A version 2.0, this time using a brutally modified electric leaf blower, was slightly more airworthy but augured in several times before becoming unflyable.

What can we learn from all this? Not much other than it would take a lot of effort to make a leaf blower fly. We appreciate all of [Peter]’s hard work here, but we think he’s better off concentrating on his beautiful homebrew ultralight instead.

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Fail Of The Week: How Not To Design An RF Signal Generator

September 6, 2018 by 25 Comments

We usually reserve the honor of Fail of the Week for one of us – someone laboring at the bench who just couldn’t get it together, or perhaps someone who came perilously close to winning a Darwin Award. We generally don’t highlight commercial products in FotW, but in the case of this substandard RF signal generator, we’ll make an exception.

We suppose the fail-badge could be pinned on [electronupdate] for this one in a way; after all, he did shell out $200 for the RF Explorer signal generator, which touts coverage from 24 MHz to 6 GHz. But in true lemons-to-lemonade fashion, the video below he provides us with a thorough analysis of the unit’s performance and a teardown of the unit.

The first step is a look at the signal with a spectrum analyzer, which was not encouraging. Were the unit generating a pure sine wave as it should, we wouldn’t see the forest of spikes indicating harmonics across the band. The oscilloscope isn’t much better; the waveform is closer to a square wave than a sine. Under the hood, he found a PIC microcontroller and a MAX2870 frequency synthesizer, but a conspicuous absence of any RF filtering components, which explains how the output got so crusty. Granted, $200 is not a lot to spend compared to what a lab-grade signal generator with such a wide frequency range would cost. And sure, external filters could help. But for $200, it seems reasonable to expect at least some filtering.

We applaud [electronupdate] for taking one for the team here and providing some valuable tips on RF design dos and don’ts. We’re used to seeing him do teardowns of components, like this peek inside surface-mount inductors, but we like thoughtful reviews like this too.

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Fail Of The Week: Solid State Relay Fails Spectacularly

August 24, 2018 by 120 Comments

A lot of times these days, it seems like we hackers are a little like kids in a candy store. With so many cool devices available for pennies at the click of a mouse, it’s temptingly easy to order first and ask questions about quality later. Most of the time that works out just fine, with the main risk of sourcing a dodgy component being a ruined afternoon of hacking when a part fails.

The stakes are much higher when you’re connecting your project to the house mains, though, as [Mattias Wandel] recently learned when the solid-state relay controlling his water heater failed, with nearly tragic results. With aplomb that defies the fact that he just discovered that he nearly burned his house down, [Mattias] tours the scene of the crime and delivers a postmortem of the victim, a Fotek SSR-25DA. It appears that he mounted it well and gave it a decent heatsink, but the thing immolated itself just the same. The only remnant of the relay’s PCB left intact was the triac mounted to the rear plate. [Mattias] suspects the PCB traces heated up when he returned from vacation and the water heater it was controlling came on; with a tank full of cold water, both elements were needed and enough current was drawn to melt the solder build-up on the high-voltage traces. With the solder gone, the traces cooked off, and the rest is history. It’s a scary scenario that’s worth looking at if you’ve got any SSRs controlling loads anywhere near their rated limit.

The morals of the story: buy quality components and test them if possible; when in doubt, derate; and make sure a flaming component can’t light anything else on fire. And you’ll want to review the basics of fire protection while you’re at it.

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Fail Of The Week: How Not To Make A 3D Scanner

July 23, 2018 by 12 Comments

Sometimes the best you can say about a project is, “Nice start.” That’s the case for this as-yet awful DIY 3D scanner, which can serve both as a launching point for further development and a lesson in what not to do.

Don’t get us wrong, we have plenty of respect for [bitluni] and for the fact that he posts his failures as well as his successes, like composite video and AM radio signals from an ESP32. He used an ESP8266 in this project, which actually uses two different sensors: an ultrasonic transducer, and a small time-of-flight laser chip. Each was mounted to a two-axis scanner built from hobby servos and 3D-printed parts. The pitch and yaw axes move the sensors through a hemisphere gathering data, but unfortunately, the Wemos D1 Mini lacks the RAM to render the complete point cloud from the raw points. That’s farmed out to a WebGL page. Initial results with the ultrasonic sensor were not great, and the TOF sensor left everything to be desired too. But [bitluni] stuck with it, and got a few results that at least make it look like he’s heading in the right direction.

We expect he’ll get this sorted out and come back with some better results, but in the meantime, we applaud his willingness to post this so that we can all benefit from his pain. He might want to check out the results from this polished and pricey LIDAR scanner for inspiration.

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