Tool Hacks

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A 1/5th scale hydraulic jack model

Miniature Hydraulic Jack Is A Scale Marvel

November 19, 2023 by 6 Comments

Most hydraulic jacks are big tools that can lift upwards of 1000 kg but [Maker B]’s is quite a bit smaller than average.

The world’s smallest hydraulic jack is a tiny hand-machined model made out of tiny pieces of iron, brass and copper. But here’s the kicker: It’s a real hydraulic jack with real hydraulic fluid! At 1/5th scale, it obviously isn’t as strong as a full-size jack, but it can still easily lift an impressive 24 soda cans! Switching between the lathe and mill, [Maker B] shows how all the parts of the jack are made from stock metal in detail, and even explains in simple terms how a hydraulic jack works in this masterpiece of a video.

Over the years, we’ve seen plenty of tiny objects cranked out from stock pieces of metal — often bolts. But the fact that the end result here is a working tool, puts it into a decidedly less common niche. Of course, given what we’ve seen from [Maker B] in the past, it’s hardly a surprise.
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A 3D Printed Grinder For Printed Lens Blanks

November 16, 2023 by 20 Comments

When one thinks of applications for 3D printing, optical components don’t seem to be a good fit. With the possible exception of Fresnel lenses, FDM printing doesn’t seem up to the job of getting the smooth surfaces and precision dimensions needed to focus light. Resin printing might be a little closer to the mark, but there’s still a long way to go between a printed blank and a finished lens.

That gap is what [Fraens] aims to fill with this homebrew lens grinding machine. It uses the same basic methods used to grind and polish lenses for centuries, only with printed components and lens blanks. The machine itself consists of a motorized chuck for holding the lens blank, plus an articulated arm to hold the polishing tool. The tool arm has an eccentric drive that wobbles the polishing tool back and forth across the blank while it rotates in the chuck. Lens grinding requires a lot of water and abrasive, so a large bowl is provided to catch the swarf and keep the work area clean.

Lens blanks are printed to approximately their finished dimensions using clear resin in an SLA printer. [Fraens] spent a lot of time optimizing the printing geometry to minimize the number of print layers required. He found that a 30° angle between the lens and the resin pool worked best, resulting in the clearest blanks. To polish the rough blanks, a lapping tool is made from polymer modeling clay; after baking it dry, the tool can hold a variety of pads and polishing compounds. From there it’s just a matter of running the blank through a range of abrasives to get the desired final surface.

Are the lenses fantastic? Well, they’re probably not going to make it into fine optical equipment, but they’re a lot better than you might expect. Of course, there’s plenty of room for improvement; better resins might result in clearer blanks, and perhaps degassing the uncured resin under vacuum might help with bubbles. Skipping the printed blanks and going with CNC-machined acrylic might be worth a try, too.

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Solder Two Boards At Once With This Dual Reflow Plate

November 10, 2023 by 4 Comments

Homebrew reflow projects generally follow a pretty simple formula: find a thrift shop toaster oven or hot plate, add a microcontroller and a means to turn the heating element on and off, and close the loop with a thermistor. Add a little code and you’re melting solder paste. Sometimes, though, a ground-up design works better, like this scalable reflow plate with all the bells and whistles.

Now, we don’t mean to hate on the many great reflow projects we’ve seen, of course. But [Michael Benn]’s build is pretty slick. The business end uses 400-watt positive temperature coefficient (PTC) heating elements from Amazon controlled by solid-state relays, although we have to note that we couldn’t find the equivalent parts on the Amazon US site, so that might be a problem. [Michael] also included mechanical temperature cutoffs for each plate, an essential safety feature in case of thermal runaway. The plates are mounted at the top of a 3D-printed case, which also has an angled enclosure for a two-color OLED display and a rotary encoder.

The software runs on an ESP32 and supports multiple temperature profiles for different solder pastes. The software also supports different profiles on the two plates, and even allows for physical expansion to a maximum of four heating plates, or even just a single plate if that’s what you need. The video below shows it going through its paces along with the final results. There’s also a video showing the internals if that’s more your style

We appreciate the fit and finish here, as well as the attention to safety. Can’t find those heating elements for your build? You might have to lose your appetite for waffles.

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Nixie Tube RPN Calculator Project

November 7, 2023 by 12 Comments

If you like Nixie tubes and/or DIY calculators, checkout this interesting talk from the HP Handheld Conference in Orlando last month by [Eric Smith] from Brouhaha and [John Doran] from Time Fracture. For 20-some years, [Eric] and the late [Richard Ottosen] have been incrementally developing various DIY calculators — this paper from the 2005 HHC conference is an excellent overview of the early project. [John] got one of those early DIY calculators and set about modifying it to use Nixie tubes. However, he got distracted by other things and set it aside — until reviving it earlier this year and enlisting [Eric]’s aid.

This presentation goes over the hardware aspects of the design. Unlike the earlier PIC-based DIY calculators, they decided to use a WCH RISC-V processor this time around. The calculator’s architecture is intentionally modular, with the display and keyboard housed in completely separate enclosures communicating by a serial interface. If the bulkiness alone doesn’t exclude it from being pocket-sized, the 170 VDC power supply and 1/2 W per digit power consumption certainly does. This modularity does lend itself to DIYers replacing the display, or the keyboard, with something different. [Eric] wants to build a mechanical flip-digit display for his unit. As for the software, [Eric] reviews the firmware approach and some future upgrades, such as making it programmable and emulating other flavors of HP calculators.

If you’re embarking on a similar project yourself, check out this talk and take notes — there are a lot of interesting tidbits on using Nixie tubes in the 21st century. If [Eric]’s name sounds familiar, you may know him from the Nonpareil calculator software used on many emulators and DIY calculator projects, one of which we covered some years ago. [John] is also a long-time tinkerer, and we wrote about his gorgeous D16/M HCMOS computer system back in 2012. Thanks to [Stephen Walters] for sending in the tip.

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What Parts Should You Desolder?

November 5, 2023 by 28 Comments

A rite of passage for a young electronics enthusiast used to be collecting an array of surplus boards from whatever could be found, and using them as sources of parts to desolder. It was possible with a bit of work and searching to build all manner of electronic projects without spending much at all.  Many hardware hackers know their way around consumer electronics from the decade before their teenage years as a result. Secondhand components can still be used, but the type of components to be found has changed, as well as those needed. [ElectricMonkeyBrain] takes a look, and asks “What should you desolder?”.

As a general rule, he lands on the premise that it’s worth hanging on to the expensive stuff rather than the cheap stuff. Large capacitors, power semiconductors, and inductors aren’t cheap at all, and in the case of the inductors they can yield both ferrite parts and enameled wire for rewinding to suit. We’re surprised that he advocates holding on to electrolytic capacitors as a kit of many values is now pretty cheap, but it’s understandable that if you lack the part and it’s there on a motherboard in front of you, it’s worth desoldering. Finally, he discusses cases, something we’ve been tempted by a few times more than we’d like to mention.

In a world of easy online ordering, it’s useful to be reminded that sometimes there’s still space for salvaged parts, after all, no delivery service is as quick as reaching under your bench for an old ATX power supply to raid. As always though, don’t amass too much of it.

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Flash Programmer Shows Some Nifty Tricks

November 5, 2023 by 12 Comments

A handy tool to have on the bench is a Flash chip programmer, and the ones based around the CH341A USB bus converter chip are readily available. But the chip is capable of so much more than simply programming nonvolatile memory, so [Tomasz Ostrowski] has created a utility program that expands its capabilities. The software provides easy access to a range of common i2c peripherals. He’s got it talking to smart batteries, GPIOs, environmental sensors, an OLED display, and even an FM radio module. The code can all be found in a GitHub repository. The software is Windows-only so no fun and games for Linux users yet — but since it’s open source, new features are just a pull request away.

The CH341A is much more than an i2C controller, it also supports a surprising range of other interfaces including SPI, UARTs, and even a bidirectional parallel printer port. Maybe this software will serve to fire the imagination of a few others, and who knows, we could see more extended use of this versatile chip. Oddly we’ve featured these programmer boards before, though in a tricky flashing job.

Homebrew TEM Cell Lets You EMC Test Your Own Devices

November 2, 2023 by 14 Comments

Submitting a new device for electromagnetic compatibility (EMC) testing seems a little like showing up for the final exam after skipping all the lectures. You might get lucky and pass, but it really would have been smarter to take a few of the quizzes to see how things were going during the semester. Similarly, it would be nice to know you’re not making any boneheaded mistakes early in the design process, which is what this DIY TEM cell is all about.

We really like [Petteri Aimonen]’s explanation of what a TEM cell, or transverse electromagnetic cell, is: he describes it as “an expanded coaxial cable that is wide enough to put your device inside of.” It basically a cage made of conductive material that encloses a space for the device under test, along with a stripline going down its center. The outer cage is attached to the outer braid of a coaxial cable, while the stripline is connected to the center conductor. Any electric or magnetic field generated by the device inside the cage goes down the coax into your test instrument, typically a spectrum analyzer.

[Petteri]’s homebrew TEM is made from a common enough material: copper-clad FR4. You could use double-sided material, or even sheet copper if you’re rich, but PCB stock is easy to work with and gets the job done. His design is detailed in a second post, which goes through the process of designing the size and shapes of all the parts as well as CNC milling the sheets of material. [Petteri] tried to make the joints by milling part-way through the substrate and bending the sheet into shape, but sadly, the copper didn’t want to cooperate with his PCB origami. Luckily, copper foil tape and a little solder heal all wounds. He also incorporated a line impedance stabilization network (LISN) into the build to provide a consistent 50-ohm characteristic impedance.

How does it work? Pretty well, it seems; when connected to a TinySA spectrum analyzer, [Petteri] was able to find high-frequency conductive noise coming from the flyback section of a switch-mode power supply. All it took was a ferrite bead and cap to fix it early in the prototyping phase of the project. Sounds like a win to us.