A Plywood Laptop For Your Raspberry Pi

[Rory Johnson] writes in to tell us about PlyTop Shell, a Creative Commons licensed design for a laser cut wooden laptop that he’s been working on since 2016. It’s designed to accommodate the Raspberry Pi (or other similarly sized SBCs), and aims to provide the builder with a completely customizable mobile computer. He’s got a limited run of the PlyTop up for sale currently, but if you’ve got the necessary equipment, you can start building yours while you wait for that new Pi 3B+ to arrive.

Originally [Rory] was working on a 3D printed design, but quickly ran into problems. The vast majority of 3D printers don’t have nearly the build volume to print out a laptop case in one shot, so the design needed to be broken up into multiple smaller pieces and then grafted together into the final case. Not only did this take a long time and a lot of material, but the final result had the rather unfortunate appearance of a plastic quilt.

Eventually he got hooked up with a maker collective in Minneapolis that had a laser cutter, and the PlyTop was born. There’s still a 3D printed component in the design that goes in the screen hinge, but the rest of the PlyTop is cut out of a three 2′ x 4′ sheets of 1/8″ Baltic birch plywood. As you might expect, plenty of fasteners are required, but [Rory] has a complete Bill of Materials (complete with purchase links) for everything you’ll need to turn the cut pieces into a fully fledged laptop. He’s considering selling kits in the future, but is still working on the logistics.

In keeping with the idea of complete flexibility, there’s no defined layout for the internals of the PlyTop. Rather, there’s an array of star-shaped openings on the bottom plate that allow the builder to connect hardware components up in whatever way works for them. [Rory] actually suggests just holding everything down with zip ties to allow for ease of tinkering.

He’s also come up with a list of suggested hardware for the keyboard, touchpad, and display; but those are really just suggestions. The design is open enough that it shouldn’t take much work to adapt to whatever gear you’ve got laying around.

Of course, this isn’t the first open source laptop we’ve seen here at Hackaday. It isn’t even the first wooden one. But we love the lines of the PlyTop and the focus on complete customization.

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New ThinkPad Guts Bring Intel Core I, DDR4, USB 3 to Cult Laptops

We often see people funneling their passion into keeping beloved devices in operation long past their manufacturer’s intent. These replacement Thinkpad motherboards (translated) bring old (yet beloved) Thinkpads a much desired processor upgrade. This is the work of the user [HOPE] on the enthusiast forum 51nb. The hack exemplifies what happens when that passion for legendary gear hits deep electrical expertise and available manufacturing. This isn’t your regular laptop refurbishment, [HOPE] is building something new.

ThinkPads are known for their zealous following (as our own [Brian Benchoff] underscored last year). Lenovo has steered the venerable brand into the future while the laptop market has drifted deeper and deeper into the wilds of tight integration at the expense of user modification. Along the way 4:3 screens were traded for media-friendly 16:9, TrackPoints were traded for trackpads, and the classic ThinkLight gave way to real keyboard backlights. These progressions left a shrinking but vocal group of old school Thinkpad enthusiasts — the cult of Thinkpad — clinging to beloved devices like 2007’s X61 and T60 ignored by a changing market.

In an astounding turn of ingenuity [HOPE] has revitalized these classic ThinkPads by entirely replacing their motherboards. And not just for one particular model, there are options available for at least 3 families of computers. The new devices are referred to by model numbers never used by IBM or Lenovo; the X60/61 motherboard makes an X62, the X200/201 motherboard makes an X210, and the T60 motherboard makes a T70. Depending on the customer’s preference either a bare motherboard or a fully assembled unit is available.

Classic stickers with non-classic ports

Depending on the exact model in question these motherboards slot directly into the original chassis but add recent generation Intel Core I processors, DDR4, USB 3.0/3.1, Thunderbolt 3 and more. Often they reuse the original heat sinks and fans, and expose these ports through the same chassis apertures the original motherboards used. Considering these machines are a decade older than the hardware being crammed inside them the level of integration is truly impressive. The end result looks like it could have come out of a Lenovo factory just before Spring Festival. If you look closely at the image at the top of this article, you might notice they even included an improved “Intel Inside” sticker on the palm rest and a model number label at the lower left of the display!

There is an implicit economic statement here that’s worth calling out. A motherboard for anything more significant than a basic microcontroller is an incredibly complicated piece of technology. When the bar is moved from “small ARM processor” up to “modern x86 system” this counts extra. Not only are they complex electrically but the fabrication processes required to physically create them are at the edge of what you’d find at your favorite cheap PCB fab house. We’re talking CPUs studded with about 1100 pins, DDR4 and PCI-E with extremely tight electrical timing requirements driving elaborate board layouts, and a plethora of off-board peripheral parts. On top of those constraints the board itself must be small enough to fit inside, not a purpose-built enclosure, but an existing laptop body with whatever combination of mounting brackets and connector placements Lenovo decided on. That a hobbyist (we assume) can make their own devices in this range to sell for $500-$700 is nothing short of astounding.

Fresh replacements being installed

This shouldn’t be possible. More accurately, it’s likely possible because there are other drivers which make the cost of PCB fabrication and assembly lower and more accessible than ever. The general march of technology certainly, but perhaps the presence of mobile devices and a desire to repair and improve them. After all and if the rumors are to be believed, anyone who can find the right Huaqiangbei stall can get the NAND replaced in their iPhone, a once complex process made simple.

It’s difficult to track the progression of each model as they are primarily covered on the 51nb forums (a Facebook page called [Lcdfans] makes some of the information available in English). However it’s possible to find hands-on information like [koobear]’s review on Reddit.

Desperately Trying to Find a Use for the ChugPlug

[AkBKukU] writes in to tell us of his experiments with the rather vile-sounding “ChugPlug”, an odd portable AC power bank designed for the express purpose of powering MacBook chargers. It would seem more efficient to simply build a DC power bank with a MagSafe connector to cut out the charger all together, but presumably there is some market for this particular niche device. Especially at the $15 they are currently selling for on Amazon.

Unfortunately, the ChugPlug that [AkBKukU] bought doesn’t seem to work. After some experimenting he found that it appears to only be outputting 80 VAC, obviously too low for many devices to function. But he reasoned that some things, like switch mode power supplies or restive loads, might still work. He just needed to come up with a way to plug them into the ChugPlug.

If his testing setup gives you a case of sweaty palms, you aren’t alone. He breaks open a dead MacBook charger to recover the female AC connector, and then solders that directly to an AC grounding adapter. The resulting pigtail lets [AkBKukU] plug in various AC loads while allowing him to probe the wires with his multimeter and oscilloscope.

Once he’s satisfied his hack works conceptually, that is, he’s able to plug arbitrary AC loads into this purpose-built battery pack, he follows up with a less dangerous looking adapter. Making use of the shell of the dead MacBook charger and what some might describe as a salacious amount of hot glue, he produces a compact and relatively safe looking device that will let him use his handicapped ChugPlug as a general purpose source of AC power.

It’s not the most elaborate portable power supply we’ve ever seen, and certainly wouldn’t be our first choice in an emergency, but at least [AkBKukU] managed to wring some use out of the thing in the end.

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Laptop with Raspberry Pi Inside Learns to Speak Battery

Early in November we took a look at a one of the best Raspberry Pi laptops we had ever seen, using the shell of a Sony VAIO. Laptops used to be hulking beasts, and that played into [Frank Adams’] hands as he got rid of the motherboard and had enough space to replace it with a Raspberry Pi and a few other support boards. This took advantage of the laptop’s screen, keyboard, LEDs, etc. But what’s a laptop without battery power? [Frank] hadn’t cracked that nut until now.

Inside of Sony VAIO laptop turned Raspberry Pi computer
VAIO battery and charging PCB seen to lower left

Adding battery power is trickier that it sounds, but [Frank] managed to get the Raspberry Pi to talk to the original Sony VAIO internal battery. His work on the project is shared, but this part of the story is best found starting on page 29 of his PDF project details.

Using the original battery is a good move since it’s designed to fit and has a charger ready to interface with the port on the laptop case. But these batteries have logic inside them, and there’s the rub. Communications use the 2-wire System Management Bus (SMBus) which is well documented. But the when trying to use the Pi’s I2C [Frank] couldn’t figure out to send a repeated start command.

He ended up writing his own C program that bit-bangs the communications he needed and now has the Pi speaking to the battery and listening to what it hears coming back. Reading through his description of this is fun since he includes his observations from a logic analyzer captures. He suspects an occasional bad read is due to Linux interrupting code execution. He watches for and catches these bad reads in software and can now reliably read all the battery vitals.

The hack leaves him with a system that functions in much the same way the original computer did: plug it in and it charges. He did add some hardware that lets him take a voltage reading from the battery using an ADC on the Teensy that was already present to control the keyboard and case LEDs. This adds a small constant draw on the battery, but for now he doesn’t leave the battery connected when the laptop is not in use.

If you’d like to read our original coverage of this laptop, here it is.

Use a Mini PCI-e 3G Card with USB Instead

Back the late 2000s, when netbooks were the latest craze, some models would come with an inbuilt 3G modem for Internet access. At the time, proper mobile Internet was a hip cool thing too — miles ahead of the false prophet known as WAP. These modems would often slot into a Mini PCI-e slot in the netbook motherboard. [delokaver] figured out how to use these 3G cards over USB instead.

It’s actually a fairly straightforward hack. The Mini PCI-e standard has a couple of pins dedicated to USB data lines, which the modem in question uses for communicating with the host computer. Unfortunately it’s not quite as simple as just soldering on a four-wire USB cable. The modem relies on the 3.3V power from the Mini PCI-e slot instead of the 5V from USB. No problem, just get a low-dropout 3.3V regulator and run that off the USB port. Then, it’s a simple enough matter of figuring out which pins are used to talk to the SIM card, and soldering them up to a SIM adapter, or directly to the card itself if you’re so inclined. The guide covers a single model of 3G modem but it’s likely the vast majority of these use a very similar setup, so don’t be afraid to have a go yourself.

Overall Mini PCI-e is a fairly unloved interface, but we’ve seen the reverse of this hack before, a Mini PCI-e to USB adapter used to add a 12-axis sensor to a laptop.

[Thanks to Itay for the tip!]

Magsafe 1 to Magsafe 2 The Cheap Way

[Klakinoumi] wanted to use their Magsafe 1 charger from 2007 with their newer Macbook Pro Retina from 2012 — but it had a Magsafe 2 port. There were a few options on the table (buy an adapter, buy a new charger, cry) but those wouldn’t do. [Klakinoumi] went with the brute force option of grinding a Magsafe 1 charger to fit Magsafe 2.

Based on the existence of passive adapters that allow Magsafe 1 chargers to work with newer laptops, we’d assume that the older chargers are probably electrically similar to the newer models. That said, it’s not our gear and we’d definitely be checking first.

With that out of the way, it’s a simple enough modification — grind away the Magsafe 1’s magnet until it fits into a Magsafe 2 port. It really is that easy. The spring-loaded pins all seem to line up with the newer port’s pads. [Klakinoumi] reports it worked successfully in their tests with 2012, 2014 and 2015 Macbooks but that it should be attempted at your own risk — good advice, as laptops ain’t cheap.

When doing this mod, consider taking care not to overheat the connector during grinding. You could both melt plastic parts of the connector, or ruin the magnet by heating it past its Curie point.

Interested in the protocol Magsafe speaks over those little golden pins? Find out here.

Q Has Nothing on Naomi Wu

We’re not so much fans of James Bond as we are of Q, the hacker who supplies him with such wonderful things. There is a challenger to Q’s crown, [Naomi Wu] — code name [SexyCyborg] — built an epic gadget called the Pi Palette which hides a Linux laptop inside of a cosmetics case.

You can see the covert mode of the Pi Palette below. It resembles a clamshell cosmetics case with the makeup and applicator in the base and a mirror on the underside of the flip-up lid. The mirror hides an LCD screen in the portrait orientation, as well as a Raspberry Pi 3 running Kali Linux.

The base of the case includes a portable battery beneath the wireless keyboard/touchpad — both of which are revealed when the cosmetics tray is removed. An inductive charger is connected to the battery and [Naomi] built a base station which the Pi Palette sits in for wireless charging.

She envisions this as a covert penetration testing. For that, the Pi Palette needs the ability to put the WiFi dongle into promiscuous mode. She wired in a dual dip-switch package and really went the extra mile to design it into the case. The fit and finish of that switch is just one tiny detail the illustrates the care taken with the entire project. With such a beautiful final project it’s no wonder she took to the streets to show it off. Check that out, as well as the build process, in the video after the break.

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