Transforming Work Light Is More Than Meets The Eye

December 4, 2020 by Tom Nardi 3 Comments

While it does use the same M12 batteries, this impeccably engineered work light isn’t an official Milwaukee product. It’s the latest creation from [Chris Chimienti], who’s spent enough time in the garage and under the hood to know a thing or two about what makes a good work light. The modular design not only allows you to add or subtract LED panels as needed, but each section is able to rotate independently so it points exactly where you need it.

Magnets embedded in the 3D printed parts mean the light modules not only firmly attach to one another, but can be stuck to whatever you’re working on. Or you could just stack all the lights up vertically and use the rocket-inspired “landing legs” of the base module keep it vertical. Even if the light gets knocked around, the tension provided by rubber bands attached to each fold-out leg means it will resist falling over. In the video after the break [Chris] says the little nosecone on top is just for fun and you don’t have to print it, but we don’t see how you can possibly resist.

The same PCB is used on both ends of the light modules.

Of course, 3D printed parts and magnets don’t self-illuminate. The LED panels and switches are salvaged from cheap lights that [Chris] found locally for a few bucks, and a common voltage regulator board is used to step the 12 volts coming from the Milwaukee battery down to something the LEDs can use. He’s designed a very slick reversible PCB that’s used on either end of each light module to transfer power between them courtesy of semi-circular traces on one side and and matching pogo pins on the other.

As we saw in his recent Dremel 3D20 rebuild, [Chris] isn’t afraid to go all in during the design phase. The amount of CAD work that went into this project is astounding, and serves as fantastic example of the benefits to be had by designing the whole assembly at once rather than doing it piecemeal. It might take longer early on, but the final results really speak for themselves.

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Circuit VR: Squaring With Schmitt Triggers

December 4, 2020 by Al Williams 6 Comments

In the fantasy world of schematic diagrams, wires have no resistance and square waves have infinitely sharp rise times. The real world, of course, is much crueler. There are many things you can use to help tame the wild analog world into the digital realm. Switches need debouncing, signals need limiting, and you might even need a filter. One of the basic elements you might use is a Schmitt trigger. In

In this installment of Circuit VR, I’m looking inside practical circuits by building Schmitt triggers in the Falstad circuit simulator. You can click the links and get to a live simulation of the circuit so you can do your own experiments and virtual measurements.

Why Schmitt Triggers?

You usually use a Schmitt trigger to convert a noisy signal into a clean square digital logic level. Any sort of logic gate has a threshold. For a 5V part, the threshold might be that anything under 2.5V is a zero and at 2.5V or above, the signal counts as a one. Some logic families define other thresholds and may have areas where the signal is undefined, possibly causing unpredictable outputs.

There are myriad problems with the threshold, of course. Two parts might not have exactly the same threshold. The threshold might vary a bit for temperature or other factors. For parts with no forbidden zone, what happens if the voltage is right at the edge of the threshold?

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Exhaust Fan-Equipped Reflow Oven Cools PCBs Quickly

December 3, 2020 by Dan Maloney 6 Comments

With reflow soldering, sometimes close is good enough. At the end of the day, the home gamer really just needs a hot plate or an old toaster oven and a calibrated Mark I eyeball to get decent results. This exhaust fan-equipped reflow oven is an attempt to take control of what’s perhaps the more challenging part of the reflow thermal cycle — the cool down.

No fan of the seat-of-the-pants school of reflow soldering, [Nabil Tewolde] started with a cast-off toaster oven for what was hoped to be a more precise reflow oven. The requisite temperature sensors and solid-state relays were added, along with a Raspberry Pi Zero W and a small LCD display. Adding the cooling assist started by cutting a gaping hole cut in the rear wall of the oven, which was then filled with a short stretch of HVAC duct and a stepper-controlled damper. The far end of the duct was fitted with a PC cooling fan; while it seems sketchy to use a plastic fan to eject hot air from the oven, [Nabil] says the exhaust isn’t really that hot by the time it gets to the fan. At the end of the reflow phase of the thermal profile, the damper opens and the fan kicks on, rapidly cooling the oven’s interior.

Unfortunately, [Nabil] still needs to crack open the oven door to get decent airflow; seems like another damper to admit fresh air would help with that. That would complicate things a bit, but it still wouldn’t be as over-the-top as some reflow builds we’ve seen. Then again, that calibrated eyeball thing can work pretty well too, even without a toaster oven.

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Hot Wire Foam Cutter Does Circles, Too

December 2, 2020 by Kristina Panos 3 Comments

Foam is all kinds of useful, but trying to cut it with scissors or a serrated plastic knife is usually an exercise in futility. What you really need is a hot wire for nice clean cuts. [Elite Worm] built a hot wire foam cutter that can cut any type of foam with ease, be it Styrofoam or grey craft foam.

There are a ton of ways to heat up a taut piece of nichrome wire, but few of them are as good looking as this one. [Elite Worm] designed and printed a table with an adjustable fence so it can be used like a table saw. There is also a circle-cutting jig that looks really handy.

This design uses a 12 V power regulator to heat up a piece of tension-adjustable nichrome wire for buttery smooth cuts. This thing looks fantastic all the way down to the cable management scheme. All the files are available on Thingiverse if you want to build one for yourself, but you’ll need to use something other than PLA.

This wire cutter is pretty versatile, but you could go even smaller with a handheld version, or build a larger, CNC-based machine.

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Scratch Building A Supersized CNC Router

November 28, 2020 by Tom Nardi 26 Comments

Many of us have spent the better part of a year on COVID-19 lockdown, and what do we have to show for it? Bit of progress on the Netflix queue? Maybe a (slightly) cleaned up garage or workshop? Not if you’re [Bob] of Making Stuff fame: he’s spent the last nine months working on a completely custom CNC router big enough to take a whole sheet of plywood.

The build is documented over a series of nearly a dozen YouTube videos, the first of which was put out all the way back in January of 2020. Seeing [Bob] heading to the steel mill to get his frame components with nary a mask in sight is a reminder of just how long he’s been working on this project. He’s also put together a comprehensive Bill of Materials on his website should anyone want to follow in his footsteps. Coming in at only slightly less than $4,000 USD, it’s certainly not a budget build. But then when we’re talking about a machine of this scale, nothing comes cheap.

Every component on this build is heavy-duty.

Even if you don’t build you own version of this router, it’s impossible to watch the build log and not get inspired about the possibilities of such a machine. In the last video we’re even treated to a bit of self-replicating action, as the jumbo CNC cuts out the pieces for its own electronics enclosure.

You can tell from the videos that [Bob] is (rightfully) proud of his creation, and isn’t shy about showing the viewer each and every triumph along the way. Even when things don’t go according to plan, there are lessons to be learned as he explains the problems and how they were ultimately resolved.

Of course, we know a home-built CNC router doesn’t need to cost thousands of dollars or take up as much space as a pool table. The average Hackaday reader probably has no need of a monster like this, and wouldn’t have anywhere to keep it even if they did. But that doesn’t mean we can’t look on with envy as we wait to see what kind of projects [Bob] churns out with such an incredible tool in his arsenal.

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HackRF PortaPack Firmware Spoofs All The Things

November 28, 2020 by Tom Nardi 45 Comments

The HackRF is an exceptionally capable software defined radio (SDR) transceiver, but naturally you need to connect it to a computer to actually do anything with it. So the PortaPack was developed to turn it into a stand-alone device with the addition of a touchscreen LCD, a few buttons, and a headphone jack. With all the hardware in place, it’s just a matter of installing a firmware capable enough to do some proper RF hacking on the go.

Enter MAYHEM, an evolved fork of the original PortaPack firmware that the developers claim is the most up-to-date and feature packed version available. Without ever plugging into a computer, this firmware allows you to receive, decode, and re-transmit a dizzying number of wireless protocols. From firing off the seating pagers at a local restaurant to creating a fleet of phantom aircraft with spoofed ADS-B transponders, MAYHEM certainly seems like it lives up to the name.

[A. Petazzoni] recently put together a detailed blog post about installing and using MAYHEM on the HackRF/PortaPack, complete with a number of real-world examples that show off just a handful of possible applications for the project. Jamming cell phones, sending fake pager messages, and cloning RF remotes is just scratching the surface of what’s possible.

It’s not hard to see why some have already expressed concern about the project, but in reality, none of these capabilities are actually new. This firmware simply brings them all together in one easy-to-use package, and while there might be an argument to be made about proliferation, we all know that the responsibility to behave ethically rests on the user and not the tools.

Building A Workshop Crane From Scratch

November 26, 2020 by Lewin Day 8 Comments

Buying tools is all well and good, but it doesn’t suit the ethos of Youtube channel [Workshop From Scratch]. Building what you need is much more the go, and that’s demonstrated ably with this home-built electric workshop crane.

The crane is put together in a straightforward manner using basic steelworking techniques. Plates and bars are machined with a drill press, bandsaw and grinder, though we could imagine you could use hand tools if you were so inclined. An ATV winch is pressed into service to do the heavy lifting, powered by a set of 12V lead acid batteries placed in the base. This design choice does double duty as both a mobile power supply for the crane, and acts as a counterweight in the base.

The final result looks sharp in its orange paint finish, and does a good job of moving heavy equipment around the workshop. The legs are reconfigurable, so that even very heavy loads can be lifted with appropriate counterweight placed on the back. It’s a significant upgrade on the earlier version we featured last year, which was hydraulic in operation. Video after the break.

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