tool hacks

A Great Way to Make Quick and Easy Knobs

August 16, 2017 by 13 Comments

Here’s a great way to quickly and easily make attractive and functional knobs with no tools required. All you need is some casting resin (epoxy would do in a pinch), a silicone mold intended for candy, and some socket head bolts. With the right preparation and a bit of careful placement and attention, smooth and functional knob ends are only minutes away. Embedded below is a short video demonstrating the process.

These may not replace purpose-made knobs for final products, but for prototypes or to use around the shop on jigs, clamps, or furniture they certainly fit the bill. With a layer of adhesive fabric or rubber, they might even make serviceable adjustable feet for low-stress loads.

This technique could be extended to reproducing broken or missing dakaware or bakelite knobs. This, of course, would require an original, unbroken knob and a small silicone mold, but it’s still a project that’s well within the capabilities of the garage-bound hacker.

While we’re on the subject of knobs, don’t forget we’ve seen an excellent method of repairing knobs as well.

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Bringing A 50 Watt Laser Cutter to Life

August 16, 2017 by 9 Comments

This is the future and we live in a world of 3D printers and laser cutters. Have you ever pondered the question of getting yourself a laser cutter? Well [Erich Styger] just landed a 50 Watt Laser Cutter from AliExpress and has written up a detailed guide to his experience.

[Erich] had been wrestling with the idea of buying one for himself for some time but was put off by the difficulty in their operation. This changed when [Scorch] published the K40 Whisperer control software which allows for better control over these machines. With the hopes of an interesting weekend project, [Erich Styger] took a leap of faith and spent $900 on a model 4040 laser cutter.

In his blog, he goes through the steps in setting up the machine as well as calibrating the laser. With a plethora of images and a detailed look at each aspect of the leveling and testing, [Erich Styger] had a weekend well spent and a working K40 laser cutter for his workshop. But perhaps the more valuable part of the stories is the overall experience.

It was not a “what you see is what you get” order, but it did turn out to be a hacker’s “what you want is what you get” adventure. The machine didn’t look the same as the picture, it came with a burned CD-R with a box full of small parts (in addition to separate shipment of a USB thumb drive and silicone sealant), and there were some mechanical touchups plus a stuck switch requiring reassembly. He has done an excellent job of documenting from order to test-runs and the photos alone are worth taking a look.

Adding value to inexpensive laser cutters in an often-featured project around here. If you are looking for more details on these wonderful machines, be sure to check out more tales of Cheap Laser Cutters and our coverage of the K40 Whisperer software launch from last month.

Pouring 1200° Tea: Foundry in a Fire Extinguisher

August 15, 2017 by 30 Comments

Let’s face it — the design of most home foundries leaves something to be desired. Most foundries are great at melting metal, but when it comes to pouring the melt, awkward handling can easily lead to horrific results. That’s why we appreciate the thought that went into this electric melting pot foundry.

Sure, electric foundries lack some of the sex-appeal of gas- or even charcoal-fueled foundries, but by eschewing the open flames and shooting sparks, [Turbo Conquering Mega Eagle] was able to integrate the crucible into the foundry body and create what looks for all the world like a Thermos bottle for molten aluminum.

The body is a decapitated fire extinguisher, while the crucible appears to just be a length of steel pipe. An electric stove heating element is wrapped around the crucible, PID control of which is taken care of by an external controller and solid state relay. Insulated with Pearlite and provided with a handle, pours are now as safe as making a nice cup of 1200° tea.

You’ll perhaps recall that [Turbo Conquering Mega Eagle] has a thing for electric foundries, although we have to say the fit and finish of the current work far exceeds his previous quick-and-dirty build using an old electric stove.

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From Handheld Bandsaw To Shop Bandsaw

August 14, 2017 by 15 Comments

If you grow up around a workshop then the chances are that you’ll have the most respect for saws. Formative years being constantly warned by parents about their risks leave an indelible mark on the nascent maker, and leave them visibly less cavalier on the matter than for example other hackspace members. The fact remains that saws offer some of the most ready opportunities for danger in your workshop. But which are the least hazardous? In the workshop near where this is being written, definitely a bandsaw is far preferable to a circular saw when it comes to finger retention.

[Making Stuff] has a portable bandsaw, contained in effect within a large handheld power tool. He’s put up a video detailing how he modified it to serve as a more conventional vertical or horizontal bandsaw, with the addition of a sturdily built welded tubular frame and table.

The video starts with the removal of the plastic surround to the trigger and  hand grip, then proceeds through the various stages of cutting, measuring, drilling, and welding. The pivot point is the crank bearing from a bicycle, and in a slightly overcomplex touch the switch is a solid state relay rather than something conventional. The metal work is well executed, and while the engineering is noting special and most Hackaday readers could do similar, it has the compelling quality of a workshop video in which everything is done right and the results are well presented. You might not make this saw, but if you had one it wouldn’t disappoint you. The full video is below the break.

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Do You Have An Endangered Craft?

August 11, 2017 by 59 Comments

It is probably fair to say that as Hackaday readers, you will all be people with the ability to make things. Some of you can make incredible things, as your writers we are in constant awe of the projects that pass through our hands. But even if you feel that your skills in the maker department aren’t particularly elite, you’ll have a propensity for work in this direction or you wouldn’t be here.

Most of the craft we feature involves technologies that are still very modern indeed to the majority of the population. We for example know that the first 3D printers were built decades ago and that we take them for granted on our benches, but to the Man In The Street they are still right up there with flying cars and time-travelling police telephone boxes.

We use 3D printers and microcontrollers because they are the tools of our age, but how different might our crafts have been if we’d been born a few centuries ago? Apprenticed to a master craftsman as teenagers, we (well, at least you boys!) would have learned  a single craft to a high level of expertise, making by hand the day-to-day products of life in those times.

The Industrial Revolution brought mechanisation and mass production, and today very few of the products you use will be hand-made. There may still be a few craftsmen with the skills to produce them by hand, but in the face of the mass-produced alternative there is little business for them and they are in inevitable decline. In an effort to do something about this and save what skills remain, the Heritage Crafts Association in the UK has published a list of dying crafts, that you can view either alphabetically, or by category of risk.

It’s a list with a British flavour as you might expect from the organisation behind it, after all for example hand stitched cricket balls are not in high demand in the Americas. But it serves also as a catalogue of some fascinating crafts, as well as plenty that will undoubtedly be of interest to Hackaday readers. Making hand-made planes, saws, or spades, for example, or at least where this is being written, coracle making.

As your Hackaday scribe this is close to home, a blacksmith carrying on her father’s business can’t earn enough to live in Southern England while an electronic engineer and technical journalist can. Eventually there will be one less blacksmith plying the craft, and though his tools and some of his skills will live on here, the business will not. Take a look at the list of crafts, do any of you have them? Or do you know of any craftspeople who have any of the skills listed, that the HCA might not know about? Let us know in the comments.

Treadle lathe image: Patrick-Emil Zörner (Paddy) [CC BY-SA 2.0].

New Release Makes EAGLE and Fusion 360 Besties

August 9, 2017 by 70 Comments

The latest release of EAGLE builds a bridge between mechanical design and electronic design. Version 8.3 rolls in the ability to synchronize between EAGLE and Fusion 360. You can now jump between mechanical design and PCB layout without the need for extra steps in between. This is the first release of EAGLE that highlights what the Autodesk purchase actually means.

Just over a year ago, Autodesk bought EagleCAD which is one of the more popular PCB design suites for students, electronic hobbyists, and Open Hardware engineers. While there were some questions about the new license structure of EAGLE under the Autodesk banner, there was a promise of a faster development schedule and the possibility for integration of EAGLE with Autodesk’s CAD programs. Now it’s finally time for EAGLE and Fusion 360 to become besties.

The EAGLE and Fusion 360 integration update includes an online library editor with managed libraries. These online libraries are the ‘cloud’ solution to a folder full of custom EAGLE libraries filled with parts. These libraries package 3D models with the EAGLE libraries, simplifying mechanical design. You can place components on your PCB, then pull that layout into Fusion 360 to see how the board will work with your enclosure. Component placements that collide with the enclosure can be adjusted in Fusion before jumping back to EAGLE to fix the routing.

Embedded passive designs. The resistors *are* the PCB.

There are a few other interesting items in the release notes for EAGLE 8.3. At the top of the list is a new ‘board shape’ object. This is more than just a milling layer for a board outline — the board shape object can now be checked with DRC to ensure components aren’t too close to an edge. This also allows for new features like customizable cutouts and embedded passive designs, or putting resistors and caps in the layers of a PCB instead of placing them as discrete components.

With this release, there is a new Single Layer Mode. This mode only highlights the active layer of the PCB, leaving all other layers grayed out. To be honest, this feature should have been in EAGLE ten years ago, but late is better than never.

For the last year, those of us not complaining about the new EAGLE licensing situation have been watching the updates to EAGLE creep out of Autodesk. There has been a lot of speculation on what Autodesk would bring to the table when it comes to electronic design. This is it. It looks like Autodesk is fulfilling their promise to integrate electronic and mechanical design. The latest EAGLE release looks great, especially with the addition of walk-around routing and something resembling push and shove traces added earlier this year, combined with this update for the mechanical side of design projects.

You can check out a promo video from Autodesk of the new EAGLE release below.

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Touchscreen Oscilloscope

August 8, 2017 by 3 Comments

[Marco Reps] didn’t want to lug a full-sized oscilloscope around to measure his ECG while running. He decided to check out the DSO112A which is a tiny touchscreen scope from the usual China sources. The tiny one channel scope can go to 2mV/division at 2MHz and can save and recall up to 24 configurations. It also has access to the data via a serial port so you can use it as a fancy data logger. [Marco’s] video appears below.

Apparently, there is was an older model without the A on the end that was not as sensitive and had some other missing features. The price is about $70–fairly inexpensive, although not throw-away cheap.

[Marco] noted that one of the two small connectors can act as an external trigger input or a function generator. There’s the typical LiPo battery inside and a shielded input section. [Marco] tears the board down and looks at the chips on the board. Inside are two Atmel CPUs and a 20 megasample per second analog to digital converter.

The color screen looks surprisingly good in the video although, as [Marco] points out, with one channel, the colors aren’t super useful. The device also has cursors and a nice selection of measurements that work both live and on stored data.

At the end of the video, [Marco] shows a simple ECG amplifier he built from an open source schematic. We’ve covered simple ECG circuits before if you want to read more.

Last year we looked at two small inexpensive scopes. Like everything else, each year the bar gets higher. Although, in fairness, those scopes had a (reported) 25 MHz bandwidth. We’d love to see that kind of front end with the user interface of the DSO112A.

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