Rolling Your Own TiVo WiFi Adapter

October 14, 2020 by Tom Nardi 16 Comments

The only thing more surprising than finding out TiVo actually put out a new 4K set-top box recently is learning that somehow they didn’t bother to build WiFi into the thing. You’re forced to buy a special wireless adapter to the tune of $60 USD to add the feature. We’d make a joke about the company living in the past, but frankly, it would be too easy.

Having to buy just one of these expensive dongles in 2020 would be insulting enough, but TiVo superfan [xxbiohazrdxx] needed four of them. Rather than hand nearly $250 to the antennae-headed overlords, they decided to reverse engineer the adapter and produce their own low-cost version. While the final result might not be as slim and svelte as the original, it does come in at less than 1/4 the price.

Operating under the assumption that the TiVo would only talk to a WiFi adapter based on the same Broadcom BCM43569 chipset used in the official one, [xxbiohazrdxx] started by trying to find a standard USB dongle that might be a drop-in replacement. Unfortunately, it looks like this particular chip was almost exclusively used in proprietary applications, most commonly as a WiFi board inside of smart TVs. But as it turns out, that wasn’t necessarily a deal breaker.

After some searching, [xxbiohazrdxx] eventually found the promising CyberTAN NU361-HS board. Not only was it based on the right chipset and ran from 5 volts, but its FCC ID entry had a complete pinout for the connector. This particular WiFi module is used in a number of budget TVs and is widely available as a spare part for less than $10. By combing the board and a USB breakout PCB inside of a 3D printed case, you’ve got a plug-and-play WiFi adapter that the TiVo thinks is the real deal.

There was a time when Hackaday was flooded with TiVo hacks, but it’s now been more than a decade since cheap carrier-provided DVRs ate the company’s lunch. Realistically, there’s an excellent chance that this post will be the only time a mention of the once-mighty DVR graces the front page in 2020. While the reign of the TiVo might be at its end, the impact it had as one of the first Linux-powered consumer devices will be etched in hacker history forever.

Designing And Building A Custom Optical Fuel Sensor

October 14, 2020 by Tom Nardi 36 Comments

At some time or another, we’ve all had an idea we thought was so clever that we jumped on the Internet to see if somebody else had already come up with it. Most of the time, they have. But on the off chance that you can’t find any signs of it online, you’re left with basically two possible conclusions. Either you’re about to enter uncharted territory, or your idea is so bad that everyone has collectively dismissed it already.

Which is precisely where [James Stanley] recently found himself. He had an idea for an non-contact optical sensor which would detect when his racing mower was about to run out of gas by analyzing light passed through a clear section of fuel hose. He couldn’t find any previous DIY examples of such a device, nor did there appear to be a commercial version. But did that mean it wouldn’t work, or that nobody had ever tried before?

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The Amazing Technicolor Parts Organizer

October 3, 2020 by Tom Nardi 9 Comments

It wouldn’t be much of an exaggeration to say that anyone reading these words has struggled at one time or another to keep an ever growing collection of electronic bits and bobs from descending into absolute chaos. Tossing them all into plastic bins is at least a start down the road to long-term organization, but they still needed to be sorted and inventoried if you want to avoid the wasted time and money of buying parts you forgot you already had.

For his latest project, [Zack Freedman] decided to finally tackle the personal parts collection that he’s ended up lugging around for the last several years. The first half of the battle was just figuring out what he actually had, what he was likely to need down the line, and getting it all sorted out so he didn’t have to keep rummaging through a big pile to find what he needed. But it’s not enough to get organized, you also need to stay organized.

Which is why he then turned his attention to how all these newly sorted components would actually be stored going forward. He already had a trio of Harbor Freight bin organizers, but as one expects from that fine retailer, they were only marginally suitable for the task at hand. So [Zack] designed a 3D printed faceplate that could snap onto the original plastic bin. The new fronts made them easier to grab and featured an opening to accept a laser-etched plastic label.

To give them a little visual flair, he decided to print the faceplates using rainbow gradient filament. To prevent them from being random colors, he used the relatively obscure sequential slicing option so his Prusa i3 would print each faceplate in its entirety before moving over to the next one on the bed. This took far longer than doing them in parallel (especially since he had access to multiple printers), but makes for a much nicer aesthetic as the color smoothly transitions between each bin on the wall. It also has a practical benefit, as you can tell at a glance if any of the bins have found themselves in the wrong spot.

If you really want to go off the deep end, we’ve seen hackers light individual bins with RGB LEDs tied into a searchable inventory system. But for most hobbyists, simply learning when to purge would be more practical.

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Building A USB-C Charger For Canon NB-4L Batteries

September 23, 2020 by Tom Nardi 17 Comments

One of the most appealing aspects of USB-C is that it promises to be a unified power delivery system. You’ll no longer need to have a separate power cords for for your phone, camera, and laptop; physically they’ll all use USB-C connectors, and the circuitry in the charger will know how much juice to send down the line for each gadget. But in reality, we’ve all got at least a few pieces of older equipment that we’re not about to toss in the trash just because it doesn’t support the latest USB spec.

Case in point, the old Canon camera that [Purkkaviritys] modified to take infrared pictures. Instead of abandoning it, he decided to make a custom USB-C charger for its NB-4L batteries. Since they’re just single cell 3.7 V lithium-ions, all he had to do was wire them up to the ubiquitous TP4056 charger module and design a 3D printed case to hold everything together.

He did go the extra mile and replace the SMD charging indicator LEDs on the PCB with 5 mm LEDs embedded into the 3D printed enclosure, though you could certainly skip this step if you were in a hurry. We imagine if you print the enclosure in a light enough color, you should be able to see the original LEDs glowing through the plastic.

This project is yet another example of how incredibly useful the TP4056 module really is. If there’s even a chance you might want to build a rechargeable gadget in the near future, you should have a few of these cheap boards ready to go in the parts bin.

Radon Monitor Recreates Steam Gauge With E-Ink

September 18, 2020 by Tom Nardi 11 Comments

While the full steampunk aesthetic might be a bit much for most people, those antique gauges do have a certain charm about them. Unfortunately, implementing them on a modern project can be somewhat tricky. Even if you’ve got a stock of old gauges laying around, you’ve still got to modify the scale markings and figure out how to drive them with digital electronics. While we’ve seen plenty of people do it over the years, there’s no debating it’s a lot harder than just wiring up an I2C display.

But maybe it doesn’t have to be. With his Rad-O-Matic, [Hans Jørgen Grimstad] created a pretty convincing “analog” gauge using a small e-ink panel. Of course it won’t fool anyone who gives it a close look, but at a glance, you could certainly be forgiven for thinking it was some kind of vintage indicator. Especially with the cracked and stained Fresnel lens he put in front of it.

For this project [Hans] used a LilyGo T5, which combines an ESP32 with a 2.13 inch electronic paper display. These are presumably meant to be development boards for digital signage applications, but they occasionally show up in hacker projects since they’re so easy to work with. The board pulls data from a RD200M radon sensor over a simple UART connection, and the current reading is indicated by a “needle” that moves across a horizontal scale on the display.

On its own, it wouldn’t look very vintage. In fact, quite the opposite. But [Hans] really helped sell the look on this project by designing and 3D printing a chunky enclosure and then weathering it to make it look like it’s been kicking around since the Cold War.

If you don’t feel like faking it, we’ve seen some very impressive projects based on authentic vintage gauges. As long as you don’t mind tearing up hardware that’s likely older than you are, putting in the extra effort necessary for a convincing modification can really pay off.

[Thanks to Tarjei for the tip.]

Arduino Takes Control Of Dead Business Card Cutter

September 10, 2020 by Tom Nardi 13 Comments

It’s a common enough situation, that when an older piece of equipment dies, and nobody wants to spend the money to repair it. Why fix the old one, when the newer version with all the latest bells and whistles isn’t much more expensive? We all understand the decision from a business standpoint, but as hackers, it always feels a bit wrong.

Which is exactly why [tommycoolman] decided to rebuild the office’s recently deceased Duplo CC-330 heavy duty business card cutter. It sounds like nobody really knows what happened to the machine in the first place, but since the majority of the internals were cooked, some kind of power surge seems likely. Whatever the reason, almost none of the original electronics were reused. From the buttons on the front panel to the motor drivers, everything has been implemented from scratch.

An Arduino Mega 2560 clone is used to control four TB6600 stepper motor drivers, with a common OLED display module installed where the original display went. The keypad next to the screen has been replaced with 10 arcade-style buttons soldered to a scrap of perfboard, though in the end [tommycoolman] covers them with a very professional looking printed vinyl sheet. There’s also a 24 V power supply onboard, with the expected assortment of step up and step down converters necessary to feed the various electronics their intended voltages.

In the end, [tommycoolman] estimates it took about $200 and 30 hours of work to get the card cutter up and running again. The argument could be made that the value of his time needs to be factored into the repair bill as well, but even still, it sounds like a bargain to us; these machines have a four-figure price tag on them when new.

Stories like this one are important reminders of the all wondrous things you can find hiding in the trash. Any time a machine like this can be rescued from the junkyard, it’s an accomplishment worthy of praise in our book.

DIY Relay Module Saves Time

September 6, 2020 by Bryan Cockfield 22 Comments

As any programmer could tell you, there’s significant value in automating a process that is performed often enough. The more times that process is used, the more it makes sense to automate it or at least improve its efficiency. This rule isn’t limited to software though; improvements to hardware design can also see improvements in efficiency as well. For that reason, [Hulk] designed a simple relay module in order to cut the amount of time he spends implementing this solution in his various other projects.

While driving a relay with a transistor is something fundamental, this project isn’t really about that per se. It’s about recognizing something that you do too much, and then designing that drudgery out of your projects. [Hulk] was able to design a PCB with 12 modules on it, presumably saving fabrication costs. He can then easily populate them with specific components as soon as he needs one. Another benefit of designing something like this yourself, rather than an off-the-shelf relay module, is that you can do away with any useless features you’ll never need (or add ones that aren’t available in commercial devices).

We can appreciate the efficiency gains this would make for our next project that needs a simple driver for a light, garage door opener, or any other binary electronic device. It can be a hassle to go find the correct transistor and relay, solder it all on the project board, and hope it all works. A pre-made solution solves all these issues, but we do wish the schematics were available to keep us from having to design our own. Driver boards are a pretty common project for all the different types of relays we see around here, so there is probably one available out there.