Tool Hacks

3030 Articles

Save An Old Drill From Landfill, With Some Lithium-Ion Magic

March 27, 2019 by 39 Comments

What do you do, when your trusty cordless drill starts to lose battery capacity? You bought it a decade ago and parts are a distant memory, so there’s no chance of buying a new pack. If you are [Danilo Larizza], you strip away the old NiMh cells, and replace them with a custom pack (Italian, Google Translate link) made from 18650 Li-ion cells.

The build is a straightforward one to anyone familiar with lithium-ion packs, but to a battery newbie it should serve as a handy step-by-step description. He starts by selecting a range of matched cells from discarded laptop batteries and adds an off-the-shelf battery management board to keep everything safe. Interestingly he appears to have soldered his wires to the cells rather than the more usual spot-welding, sadly for many of us a spot-welder is beyond our means. It would be interesting to know both the mechanical integrity of the resulting connection and whether the heat of soldering might in some way affect the cells.

Firing up the drill with the new pack is not the immediate success he hoped it would be, the start-up current is so high that the battery management board goes into a fault condition. This situation is resolved with a model that can take more current, and he can take his drill out once more.

If you are annoyed by the rise of cordless tools, you’re in good company. Meanwhile if you lack a spot-welder for batteries, have a look at one of the nicer ones we’ve seen.

Testing A Battery-Powered Mini Spot Welder

March 25, 2019 by 27 Comments

Did you ever see a thin metal tab bonded to a battery terminal with little pock marks? That’s the work of a spot welder. Spot welding is one of those processes that doesn’t offer much in the way of alternatives; either one uses a spot welder to do the job right, or one simply does without. That need is what led [Erwin Ried] to purchase a small, battery-powered spot welder from a maker in Korea and test it out on nickel strips.

The spot welder [Erwin] used is the work of a user by the name of [aulakiria] (link is Korean, machine translation here) and is designed to be portable and powered by batteries commonly used for RC. [Erwin] is delighted with the results, and demonstrates the device in the video embedded below.

Spot welder projects see a lot of DIY, some of which are successful while others are less so. Our own [Sean Boyce] even gave making a solar-powered spot welder a shot, the results of which he described as “nearly practical!”

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Create Green, Soldermasked PCBs With Fritzing

March 22, 2019 by 12 Comments

Even though you can easily order a PCB from any one of a dozen board houses and have it on your desk in a few weeks, there’s still a need for home-made circuit boards. If it’s because you have very special or strange requirements, you want to save money, or you need to suffer for your art, you can make printed circuit boards at home. You can even apply soldermask. It’s easy, and [Renzo] is here to show you how.

The beginnings of this tutorial cover well-tread territory such as building a CNC router, laying out a circuit, and cutting a piece of single-sided, copper clad board. If you stopped right there, after milling traces into a board, you would have a functioning circuit. But it wouldn’t look good; a piece of copper does not a PCB make, and you need soldermask. That’s where the real work comes in.

Applying the soldermask meant there needed to be places without soldermask, mostly the vias and through-holes. For this, [Renzo] pulled the copper pad layer out of Fritzing, printed it on a transparency sheet, and finally applied the UV-curing soldermask. This came as a kit, and right now, you can get 10 ml of green, red, blue, yellow, and black UV-curing soldermask, and a UV flashlight for ten dollars on the usual Internet shops. This soldermask was lathered on, rolled out, and exposed with the UV flashlight. After a quick wash in acetone, the result is a perfect PCB.

Spotting Scope Mount Makes For More Comfortable Target Scoring

March 16, 2019 by 15 Comments

One of the big bottlenecks in target shooting is the scoring process. Even if it’s not a serious match, it’s still important to know where holes have landed because it’s important feedback on technique and performance. A spotting scope, which is really just a kind of telescope optimized for getting a sharp view of a distant target, is often used to see hits on a target without leaving the firing line. Usually they’re mounted on tripods and optimized for seated use, but [Steve Thone] came up with a clever hack for more comfortable use and mounting that works better for him while engaging in bulls-eye shooting from the standing position.

[Steve] took a ratcheting bar clamp and drilled a few holes near the end of the bar. Using these holes, the spotting scope is mounted directly to the bar and the clamp grips a shooting table or bench in place of a stand. He also put a 90 degree twist in the bar so that the clamp and scope could be oriented perpendicular to one another.

The result is a quick and easy-to-use mounting solution that, unlike a tripod, doesn’t eat up precious table space. Stability may be inferior to a tripod, but it’s serviceable enough that other shooters showed up with their own versions the week after [Steve] used his. After all, target shooters tend to be DIY types with an interest in both low-tech hacks like this one as well as higher-tech projects like rifle-mounted sensors.

This Vibrating Continuity Tester Is Quietly Useful

March 14, 2019 by 21 Comments

Continuity testing is one of the most valuable functions on the modern multimeter. It will help you investigate wiring problems in your car, tell you if you’re holding a nullmodem serial cable or the regular kind, and even reveal when you’ve accidentally shorted the data lines right to the power supply. However, all that beeping can get annoying, so [bitelxux] built a vibrating version instead.

The build was borne out of necessity; [bitelxux]’s meter lacked a buzzer, and it grew frustrating to always look at the display. In order to allow late night hacking sessions to go on undisturbed, an unobtrusive vibrating tester was desired, as opposed to the usual audible type. Two whiteboard markers donated their shells to the hack, fitted with small nails to act as probes. Inside, a pager vibration motor is connected, vibrating when continuity is found. The circuit runs from a 1.5V AA battery which neatly fits inside the marker shell.

It’s a basic build, but gets the job done with a minimum of fuss using parts that most makers probably have lying around. Of course, you can always go a slightly more complicated route and throw an Attiny at the problem.

Downdraft Table Inhales Dust, Not Cash

March 14, 2019 by 15 Comments

We always look forward to the builds [MakerMan] sends in, and it’s not just because we dig his choices in royalty free music (though it helps). He always manages to put together his projects with a minimum of fuss, and perhaps more importantly, a minimum of funds. His builds use salvaged components, easily sourced materials, and common tools. Watching him work invariably makes us realize that we tend to overthink our own projects.

In his latest video, [MakerMan] was tasked with building a downdraft table for a local factory that makes jewelry boxes. By sucking air through a series of holes in the table’s surface, sawdust created while the workers are building the boxes will automatically be removed from the workspace. Even if you aren’t in the jewelry box making business, any task which produces fine particles (such as sanding) could benefit from such a setup. You probably won’t need a downdraft table quite as large as the one he builds, but the principles will be the same if you get inspired to build a somewhat smaller version.

The build starts with sheets of MDF, which get cut, glued, and screwed together to make the basic tabletop shape. To this, [MakerMan] attaches a welded steel frame which will give it the strength MDF itself lacks. With careful measurement, lines are plotted across the top of the MDF sheet and all the holes are drilled with a simple hand drill; no fancy CNC here.

With the table doing its best colander impression, [MakerMan] adds an air box to the bottom which is similarly made of thin MDF sheets. All of the joints are sealed up with caulk, because at this point you want things to be as air tight as possible. A large blower is attached to the bottom, which gets piped to a dust collection system that’s made of a garbage can and…you guessed it, more MDF.

Watching [MakerMan] turn what’s often literal trash into a functional build never gets old. We’ve seen him create everything from a gorgeous origami chandelier to a very impressive diode laser cutter using little more than scrap parts and hand tools, and we can’t wait to see what he comes up with next.

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[Ben Krasnow] Drills Really Small Holes With Electricity

March 14, 2019 by 21 Comments

Drilling holes is easy; humans have been doing it in one form or another for almost 40,000 years. Drilling really tiny holes in hard materials is more challenging, but still doable. Drilling deep, straight holes in hard materials is another thing altogether.

Luckily, these days we have electric discharge machining (EDM), a technique that opens up all kinds of possibilities. And just as luckily, [Ben Krasnow] got his hands on some EDM gear to try out, with fascinating results. As [Ben] explains, at its heart EDM is just the use of a small arc to ablate metal from a surface. The arc is precisely controlled, both its frequency via an arc controller, and its location using CNC motion control. The arc controller has always been the sticking point for home EDM, but the one [Ben] tried out, a BaxEDM BX17, is squarely aimed at the small shop market. The whole test platform that [Ben] built has a decidedly home-brew look to it, with a CNC gantry rigged up to a water tank, an EDM drill head spinning the drill rods slowly, and an airless paint gun providing high-pressure process fluid. The video below shows that it works remarkably well nonetheless.

While we’re certainly keen to see [Ben]’s promised videos on EDM milling and cutting, we doubt we’ll line up to shell out €2,950 for the arc controller he used. If you have more courage than money, this mains-powered EDM might be a better fit.

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