Hydroforming In The Garage With A Pressure Washer

August 13, 2014 by James Hobson 74 Comments

Ever heard of hydroforming? It’s a manufacturing process used to form sheet metal into shapes using water at extremely high pressures. Not something you can do at home… unless of course you’re [Colin Furze].

Hydroforming works by evenly distributing pressure via water (conveniently, in-compressible) against sheet metal inside of a mold. Many automotive parts are created in this fashion. Typical systems run at around 15,000 PSI.

After building a giant pulse jet engine (complete with butt) to fart on France, [Colin] got the idea from a YouTube comment to try to do hydroforming at home — bending the sheet metal for the giant derriere wasn’t that easy. Hydroforming on the other hand is a surprisingly simple process. Weld some sheet metal together, add a pipe fitting to connect your cheap pressure washer and boom — hydoformed metal parts.

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And So Castings Made Of (Kinetic) Sand . . . Turn Out Pretty Well, Actually

August 12, 2014 by Kristina Panos 35 Comments

That kinetic sand stuff is pretty cool. It’s soft, it builds motor skills, and outside of sprinkling it on carpet, it’s not messy. If you don’t know, it’s 98% sand and 2% polydimethylsiloxane, which is a major component of Silly Putty, and according to a certain yellow and red clown, it’s safe enough to put in chicken nuggets. [Chris]’s wife bought him some, probably because she wanted to see him play around with something that isn’t potentially deadly for a change. In the course of researching its magical properties, he found out that it doesn’t really have a thermal breakdown point, per se. At high enough temperatures, It vitrifies like a sand castle in a mushroom cloud. Between this property and its malleability, [Chris] thought he’d have a reasonable substitute for founding sand. As you can see in his latest experiment, he was right. As a bonus, he managed to turn the benign into the dangerous.

[Chris] had never cast aluminium before, so he decided to start small by making an offset cam for a rotary broach. He packed some magic sand in a wax paper cup and shoved the cam in to make the negative. Then he cut down some aluminium rod and put it in a graphite crucible. He stuck his DC arc welder’s electrode down into the crucible and cranked it up to 50A. That wasn’t enough, so he went to 110. The crucible was soon glowing orange. He carefully poured the molten aluminium into the mold. Make the jump to see how it panned out.

Spoiler alert: there’s no cussin’ this time!

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Homemade Soldering Station for cheap Soldering Irons

Homemade Soldering Stations For Cheapy Irons

August 10, 2014 by Rich Bremer 32 Comments

Everyone reading this post has had a cheap pencil-style soldering irons that plug straight into the wall at some point in their lives. Even if you’ve upgraded to a professional soldering station, you probably have one of these cheapy irons kicking around that are slow to heat up to an unknown temperature. [Pantelis] thought he could fix the latter problem with his Homemade Soldering Station for those basic soldering irons.

Since the intent of the soldering station was to control the temperature of the iron [Pantelis] had to figure out a way to sense the temperature. He did this by strapping a thermocouple to the iron near the tip. The wires were run back through the handle and then along the power cord.

Both the stock iron plug and the thermocouple leads plug into a box put together specifically for this project. In the photo you’ll notice the LCD screen that displays both the target and actual temperatures. The linear potentiometer below the LCD screen is used to set the target temperature. The LED to the right alerts the operator that the iron is heating up and when it is at temperature and read to go.

Although there isn’t a lot of schematic or part list information, [Pantelis] did do a good job photo documenting his build. Check it out, it’s worth a gander.

Finding And Repairing Microscopes From The Trash

August 2, 2014 by Brian Benchoff 24 Comments

scope We’re not quite sure where [Andy] hangs out, but he recently found a pile of broken microscopes in a dumpster. They’re old and obsolete microscopes made for biological specimens and not inspecting surface mount devices and electronic components, but the quality of the optics is outstanding and hey, free microscope.

There was a problem with these old scopes – the bulb used to illuminate specimens was made out of pure unobtainium, meaning [Andy] would have to rig up his own fix. The easiest way to do that? Some LEDs made for car headlights, of course.

The maker of these scopes did produce a few for export to be used in rural areas all across the globe. These models had a 12 Volt input to allow the use of a car battery to light the bulb. A LED headlight also runs off 12 Volts, so it was easy for [Andy] to choose a light source for this repair.

A little bit of dremeling later, and [Andy] had the new bulb in place. An off the shelf PWM controller can vary the brightness of the LED, controlled with the original Bakelite knob. The completed scope can easily inspect human hairs, the dust mites, blood cells, and just about anything down to the limits of optical microscopy. Future plans for this microscope might include another project on hackaday.io, a stage automator that will allow the imaging of huge fields at very high magnification – not bad for something pulled out of the trash.

Solar Powered Lawn Mower Cuts The Grass So You Don’t Have To

August 1, 2014 by Matt Terndrup 23 Comments

MowerFea2

It takes a lot of power and energy to keep grass levels down to an appropriate level; especially when it’s hot out. If cool glasses of lemonade aren’t around, the task at hand may not be completed any time soon causing the unkempt blades of green (or yellow) vegetation outside to continue their path of growth towards the sun.

Instead of braving the oven-like temperatures which will inevitably drench the person in sweat, this solar powered robot has been created ready to take on the job. With the heart of an Arduino, this device shaves down the grass on a regular basis, rather than only chopping down the material when it gets too long. This helps to save electricity since the mower is only dealing with young and soft plants whose heads are easily lopped off without much effort.

Internally, the robot’s circuitry interfaces with an underground wiring system that defines the cutting zones within the lawn, and proves to be a simple, accurate, and reliable approach to directing the robot where to go. If the device travels under a shaded area, a battery kicks in supplying energy to the engine. When sunlight is available, that same battery accumulates the electricity, storing it for later.

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This Hackaday Prize Entry Sucks

July 31, 2014 by Brian Benchoff 11 Comments

Sucker [K.C. Lee] is busy working on his entry to The Hackaday Prize, and right now he’s dealing with a lot of assembly. For his entry, that means tiny SMD parts, and the vacuum pen he ordered from DealExtreme hasn’t come in yet. The solution? The same as anyone else who has found themselves in this situation: getting an air pump for an aquarium.

For this quick build until the right tool has time to arrive from China, [K.C.] took an old fish pump and modified it for suction. He doesn’t go over the exact modification to the pump, but this can be as easy as drilling a hole and stuffing some silicone tubing in there.

The ‘tool’ for this vacuum pen is a plastic disposable 0.5mm mechanical pencil. [K,C.] found this worked alright on smaller parts down to 0402 packages, but heavy parts with smooth surfaces – chips, for example – are too much for the mechanical pencil and aquarium pump to handle.

16-Bobbin Rope Braiding Machine Inspired By Surplus Store Find

July 29, 2014 by Mike Szczys 34 Comments

When the Red Bull Creation build days were past, [David] pulled us aside and asked if we wanted to see the mechanical hack he’s been working on. He built this rope braiding machine, which uses 16 bobbins, with help from his brother [Jed].

Ideas for projects always come from funny places. [David] came up with this one after finding a rope braiding machine at Ax-man Surplus. This outlet, located in the Twin Cities (Minneapolis/St. Paul, Minnesota) has been the origin for innumerable hacks. Just one that comes to mind is this electric scooter project from the ’90s.

[David] wanted to understand how the mechanism, which divides the bobbins up into groups of orbiting spools, actually works. It’s both mesmerizing and quite tough to visualize how it works without really getting in there and looking at the gearing. Thankfully you can do just that if he follows through with his plan to turn this into a kit.

In case you don’t recognize him, [David] was on the 1.21 Jigawatt’s team during this year’s Creation. We’ve also seen a couple of hacks from him in the past like this half-tone drum printer, and this bicycle frame welding jig.