Drilling Perfectly Centered Holes

February 26, 2010 by Jakob Griffith 38 Comments

If you’ve ever been caught in the situation of needing to drill a clean straight hole down the center of a bolt or rod, you’ve probably tried and ended up with a broken bit or tilted hole, and a ton of cursing to boot.

[Vik] let us know about this nifty trick for drilling ‘down the middle’ using a simple hobby drill press and vice. He claims it’s ‘physics guiding the bit’ but in reality its just crafty use of a chuck. Either way the quick trick works, and will hopefully save a lot of hackers some headaches in the future.

Let us know in the comments if you have any simple quick tips that you use when you’re out in the shop.

Nokia USB Cable Is USB-to-Serial In Disguise

February 25, 2010 by Mike Szczys 43 Comments

[Jethomson] worked out a way to use a Nokia USB cable at a USB to Serial cable. He was able to pick up one of these cables for less than $3 delivered. A little probing worked out which conductors go with the appropriate signals and from there he developed a way to protect the 3.3v signal levels with a voltage divider.

It’s not surprising that this works, having seen [Will O’Brien’s] post covering serial communications on Nokia phones. In that post we learned that the Nokia phones are using TTL communications. Once you’ve completed [Jethomson’s] modifications to the cable you can follow his examples for using this in conjunction with an Arduino.

10-bit Rotary Precision For Servos

February 24, 2010 by Mike Szczys 22 Comments

[Antonb] added 10-bit encoding to a standard servo. He’s removed the potentiometer, separated its shaft and used it to rotate a small magnet. By sandwiching an AS5040 rotatory encoder IC into the servo’s housing he can now measure the precise orientation of the servo horn. This is made easier by his tiny breakout board for the chip. If you want to layout your own PCB you can download the EagleCAD files for this device. Take a look at the final product in the clip after the break.

Continue reading “10-bit Rotary Precision For Servos” →

Lathe Modification

February 18, 2010 by Caleb Kraft 21 Comments

[youtube=http://www.youtube.com/watch?v=maB28gXoZV4]

The folks over at NerdKits got a shiny new Smithy 1220xl lathe/ mill. They found, however that adjusting the Z axis wasn’t as accurate as they desired. They decided to resolve this by installing a digital caliper and an LCD interface to display the adjustments. The writeup is quite detailed and the results seem to work great.

Microscope Lens Hack

February 16, 2010 by Mike Szczys 21 Comments

Who doesn’t need to take pictures of the microscopic bits inside of an integrated circuit? [Mojobojo] made an end-run around the expensive equipment by building a microscopic lens from an old camcorder. He’s using a regular digital camera with the lens set to its largest zoom level. The camera is pointed into the salvaged camcorder lens where the fine tuning is done. His first iteration was just taped to the desk with a small hand flashlight illuminating the subject. He upgraded that setup by building a LEGO enclosure and changing to a much brighter light source. The images he’s getting are quite surprising and this will be very useful during those extreme hacks when you need to tap into an IC’s internal data rails.

[Thanks Julius]

Transparent Rubber Enclosures

February 12, 2010 by Mike Szczys 31 Comments

This clear rubber puck serves as the enclosure for a diy mp3 player. The wires encapsulated in the rubber are just there for looks but the utility of using this material as a case is fascinating. Alas, there’s no details on the material other than that it’s clear rubber. Update: [Reboots] picked up on some info that we originally missed. Looks like this is made from some Smooth-On PCM 780 urethane rubber.

We’ve looked into casting our own molds from silicone rubber in the past. That may be the process used here but we can’t tell what allows the two halves to be pried apart. We’ve embedded video after the break that details casting rubber around a part in one solid block, then cutting the rubber off of that to create a mold. We’re also familiar with the mold making kits from Tap plastics but as far as we know, they’re always colored and never clear.

We keep our eyes peeled for new prototyping products and we want to know more about the materials and the process used to make this cylindrical elastomer. If you’ve got the goods on how this is done, please share them in the comments.

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Use An Analog Oscilloscope To Display Digital Logic

February 11, 2010 by Mike Szczys 31 Comments

[Mike Bradley] wanted to use his oscilloscope to display 8 channels of digital signals. Alas, the analog unit didn’t have this capability. Not to worry, he threw together an adapter module that does the trick. Using a PIC 18F26K20 microcontroller he inputs four or eight channel digital logic (at 5V) and filters the output to an analog signal that the oscilloscope can interpret. What you see in the photo above is the result.