Zippo Keeps Your Bits Safe

April 20, 2018 by Adam Fabio 29 Comments

[Laura Kampf] found a new use for an old Zippo lighter by turning it into a carrier for her screwdriver bits. There are several multitools out there which can accept standard screwdriver bits. The problem is carrying those bits around. Leaving a few bits in your pocket is a recipe for pocket holes and missing bits.

[Laura’s] solution uses her old Zippo lighter. All she needs is the case, the lighter element itself can be saved for another project. A block of aluminum is cut and sanded down to a friction fit. Laura uses a band saw and bench sander for this. The aluminum block is then drilled out to fit four bits. Small neodymium magnets are taped into the holes with double-sided tape. These magnets retain the bits, ensuring none will fall out when the lighter is opened.

This is a great quick project and an excellent way to carry four bits. We’re curious if the second set of holes (and a shorter bar) could expand this carrier to 8 bits – 4 on top and 4 on the bottom. [Laura] noticed this too, but decided to keep the build simple with 4 bits.

We love Every Day Carry (EDC) projects like this – in fact, a few years back we had our own EDC contest featuring the Adafruit Trinket. Check out the awards announcement post for some awesome pocket projects!

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Dispensing Solder Paste Automatically

April 18, 2018 by Brian Benchoff 48 Comments

Through-hole chips are slowly falling by the wayside, and if you want to build something with new parts you will be using surface mount components. This means spreading paste and throwing it in the toaster oven. Of course, if you don’t want to take the time to get a stencil for your solder paste, you can always lay it down by hand. For that, [owhite] has created a tiny, handheld, robotic solder paste dispenser. It’s a robotic pen that dispenses just the right amount of solder paste on your pads.

The design of this solder paste dispenser is basically a syringe filled with paste and a stepper motor to push the plunger down. Devices like this already exist, and the i-extruder can be had for somewhere around two hundred bucks. Why buy when you can build, so [owhite] set out to create his own.

The key to a successful solder paste pen, it seems, is driving the plunger with a small NEMA 8 stepper motor, using a very fine pitch on the threads of the gears pushing the plunger down, and surprisingly finding a small-diameter syringe. [owhite] found the last bit in the form of a gas-tight syringe with a nylon gasket. The electronics consist of just a Teensy 3.2, DRV8825 stepper driver, footswitch, and an OLED for a UI.

With just a few parts, [owhite] managed to create a solder paste pen that’s better than the commercial i-extruder, and with a bit of practice can be used to place paste on some SMD pads.

Superb Wood Floor Inlay Shows Off Computer-Augmented Tools

April 15, 2018 by Kerry Scharfglass 24 Comments

It’s been a few years since we first started hearing about “tools of the future changing the way we work” but this astounding whole-room floor inlay might be the best argument for them yet.

A couple of years ago we wrote a hands-on preview of a unique tool called the Shaper Origin. If a milling machine is classically defined as having a stationary tool head with moving stock, the Origin is the reverse. To use an Origin the user adheres specially marked tape to the stock material, then holds the origin down and moves it much like a hand router.

The Origin has a camera which tracks the fiducial patterns on the tape, allowing it to know its precise position, even across an entire room. The operator sees a picture on the screen of the tool that guides them with superimposed lines, while the tool head makes its own precision adjustments to perfectly cut the design in the X, Y, and Z.

But what do you use a tool like this for? Cutting boards, small tables, and toy blocks are fine examples but don’t highlight any unique features of the tool. Many could just as easily be made using a ShopBot, X-Carve, Carvey, or any of their ilk. What you can’t do with any of those tools (or really anything besides manual labor, endless patience, and master skill) is inlay an entire floor in situ.

[Mark Scheller] (eight time winner of Wood Floor of the Year awards) used an Origin to cut a curvaceous 22 foot long rendition of the first 9 bars of Handel’s Passacaglia into the floor of a lucky homeowner’s music room. Without decades of practice, it’s difficult to imagine doing this any way besides with a Shaper Origin. You can’t put an entire room into a CNC router. The individual floorboards could be cut, but that would be tedious and increasingly difficult as the room gets larger. With the Origin it seems almost trivial. Do the design, place the marking tape, and cut. The same model is used to cut the inlays for a perfect fit. This is an incredible example of a unique use for this unusual tool!

A Machinist’s Foray Into Jewelry Making

April 12, 2018 by Brian McEvoy 10 Comments

Machinists are expected to make functional items from stock material, at least hat’s the one-line job description even though it glosses over many important details. [Eclix] wanted a birthday gift for his girlfriend that wasn’t just jewelry, indeed he wanted jewelry made with his own hands. After all, nothing in his skillset prohibits him from making beautiful things. He admits there were mistakes, but in the end, he came up with a recipe for two pairs of earrings, one set with sapphires and one with diamonds.

He set the gems in sterling silver which was machined to have sockets the exact diameter and depth of the stones. The back end of the rods were machined down to form the post for the clutch making each earring a single piece of metal and a single gemstone. Maintaining a single piece also eliminates the need for welding or soldering which is messy according to the pictures.

This type of cross-discipline skill is one of the things that gives Hackaday its variety. In that regard, consider the art store for your hacking needs and don’t forget the humble library.

Emulating OBD-II On The ESP32

April 11, 2018 by Tom Nardi 35 Comments

It used to be that you could pop the hood and with nothing more than flat head screwdriver, some baling wire, and tongue held at the optimal angle, you could fix anything that ailed your car. But today, for better or for worse, the average automobile is a rolling computer that runs on gasoline and hope (if it even still has a gasoline engine, that is). DIY repairs and maintenance on a modern car is still possible of course, but the home mechanic’s toolbox has needed to evolve with the times. If you want to do anything more advanced than changing a tire, you’ll really want to have the gear to interface with the vehicle’s computer via the OBD-II port.

But for some, even that isn’t enough. [limiter121] recently wrote in to tell us of an interesting project which doesn’t read the OBD-II port in a vehicle, but actually emulates one. Like so many others this hack was born out of necessity, as a way to test an OBD-II project without having to sit out in the driveway all day. It allows you to create fictitious speed and engine RPM values for the OBD-II device or software under test to read, complete with a slick web interface to control the “car”.

So what makes it tick? Surprisingly little, actually. At the most basic level, an ESP32-WROOM-32 is connected up to a SN65HVD230 CAN transceiver chip. You’ll also need a 3.3V power supply, as well as a USB to serial adapter to do the initial programming on the ESP32. From there it’s just a matter of compiling and flashing the code [limiter121] has made available in the GitHub repo.

If you’re wondering if such products don’t already exist on the commercial market, they do. But like so many other niche projects, the price is a bit hard to swallow for the home hacker. Compared to the nearly $300 USD list price of commercial offerings such as the Freematics OBD-II Emulator, building one of these ESP32 based emulators should only cost you around $20.

Unless you’re developing an OBD-II reader, you probably don’t have much use for an OBD-II emulator. But this project could still be useful for anyone who wants to learn more about OBD from the comfort of their couch.

Micro Chainsaw Gets A Much Needed Nitro Power Boost

April 10, 2018 by Dan Maloney 25 Comments

When life hands you the world’s smallest chainsaw, what’s there to do except make it even more ridiculous? That’s what [JohnnyQ90] did when he heavily modified a mini-electric chainsaw with a powerful RC car engine.

The saw in question, a Bosch EasyCut with “Nanoblade technology,” can only be defined as a chainsaw in the loosest of senses. It’s a cordless tool intended for light pruning and the like, and desperately in need of the [Tim the Toolman Taylor] treatment. The transmogrification began with a teardown of the drivetrain and addition of a custom centrifugal clutch for the 1.44-cc nitro RC car engine. The engine needed a custom base to mount it inside the case, and the original PCB made the perfect template. The original case lost a lot of weight to the bandsaw and Dremel, a cooling fan was 3D-printed, and a fascinatingly complex throttle linkage tied everything together. With a fuel tank hiding in the new 3D-printed handle, the whole thing looks like it was always supposed to have this engine. The third video below shows it in action; unfortunately, with the engine rotating the wrong direction and no room for an idler gear, [JohnnyQ90] had to settle for flipping the bar upside down to get it to cut. But with some hacks it’s the journey that interests us more than the destination.

This isn’t [JohnnyQ90]’s first nitro rodeo — he’s done nitro conversions on a cordless drill and a Dremel before. You should also check out his micro Tesla turbine, too, especially if you appreciate fine machining.

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Simple Mechanism Gives Support For SMT Assembly

April 10, 2018 by Dan Maloney 15 Comments

With the fine work needed for surface-mount technology, most of the job entails overcoming the limits of the human body. Eyes more than a couple of decades old need help to see what’s going on, and fingers that are fine for manipulating relatively large objects need mechanical assistance to grasp tiny SMT components. But where it can really fall apart is when you get the shakes, those involuntary tiny muscle movements that we rarely notice in the real world, but wreak havoc as we try to place components on a PCB.

To fight the shakes, you can do one of two things: remove the human, or improve the human. Unable to justify a pick and place robot for the former, [Tom] opted to build a quick hand support for surface-mount work, and the results are impressive considering it’s built entirely of scrap. It’s just a three-piece arm with standard butt hinges for joints; mounted so the hinge pins are perpendicular to the work surface and fitted with a horizontal hand rest, it constrains movement to a plane above the PCB. A hole in the hand rest for a small vacuum tip allows [Tom] to pick up a part and place it on the board — he reports that the tackiness of the solder paste is enough to remove the SMD from the tip. The video below shows it in action with decent results, but we wonder if an acrylic hand rest might provide better visibility.

Not ready for your own pick and place? That’s understandable; not every shop needs that scale of production. But we think this is a great idea for making SMT approachable to a wider audience.

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