Automatic Dust Collection For The Whole Shop

January 5, 2018 by Tom Nardi 19 Comments

If you’ve got a woodworking area, or even if you’ve just got something that really churns out dust like a belt sander or table saw, there’s an excellent chance you hate sawdust with a passion. It gets all over your clothes, jams up everything mechanical, and as a fun little bonus can be explosive if not handled properly. Thankfully newer tools tend to come with their own dust collection bags (back in the old days, you weren’t really a man unless you were coughing up wood fibers), but if you’ve got a half a dozen tools with half a dozen different dust bags you’ve got to empty, that can get pretty annoying.

Especially if you take woodworking as seriously as [Brad Wright] does. Over on his YouTube channel [DIY Builds], he quickly runs through the construction of a whole-shop dust collection system with some very neat features. Not everyone needs a system this intricate, but the tips and tricks he shows off during the build are great and can certainly be adapted to less grandiose setups.

Dust collection connector with closeable gate — One of the scratch-built gates.

[Brad] goes into a bit more detail in this gallery, revealing that the heart of the build is a Harbor Freight dust collection system that he modified into a cyclone separator. Big chunks fall down into the 55 gallon bucket, and what’s left gets blown out of the shop via a louvered vent through an exterior wall. An intricate system of 4 inch PVC pipe is then used to connect up each individual machine’s dust collection port. Even individual hand sanders get into the act via a three way manifold. His table saw lacked a dust port, so he enclosed the motor with a piece of plywood and made his own.

One of the most interesting aspects of the build is the scratch-built blast gates. These are essentially valves which open and close the different sections of the PVC where they mate to the individual stations. This prevents the dust collection system from wasting suction by trying to pull from all the stations at once when only one is in use at any given time. [Brad] even wired up the blast gates with switches that will turn the dust collection system on when the gate is open, and off when it’s closed.

This isn’t the first time we’ve covered the lengths people will go to rid their shop of dust. Cyclone dust separators are an especially popular build, using everything from sheet metal to 3D printed parts.

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Spite, Thrift, And The Virtues Of An Affordable Logic Analyzer

January 3, 2018 by Dan Maloney 44 Comments

[Larry Wall], the father of Perl, lists the three great virtues of all programmers: Laziness, Impatience, and Hubris. After seeing that Saleae jacked up the prices on their popular logic analyzers to ludicrous levels, [CNLohr] added a fourth virtue: Spite. And since his tests with a Cypress FX3 over the last few days may lead to a dirt-cheap DIY logic analyzer, we may soon be able to add another virtue: Thrift.

The story begins a year or two ago when [CNLohr] got a Cypress FX3 development board for $45. The board sat unused for want of a Windows machine, but after seeing our recent article on a minimalist logic analyzer based on an FX2, he started playing with the board to see if it could fan the flames of his Saleae hatred. The FX3 is a neat little chip that has a 100-MHz General Programmable Interface (GPIF) bus that basically lets it act like an easy to use FPGA.

Prepared to spend months on the project, he was surprised to make significant progress on his mission of spiteful thrift within a few days, reading 16 bits off the GPIF at over 200 megabytes per second and dumping it over the USB 3.0 port. [Charles]’ libraries for the FX3 lay the foundation for a lot of cool stuff, from logic analyzers to SDRs and beyond — now someone just has to build them.

The search for a cheap but capable logic analyzer is nothing new, of course. Last year, both [Jenny List] and [Bil Herd] looked at the $22 iCEstick as a potential Saleae beater.

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Print A Sacrificial Magnet Square

January 2, 2018 by Kristina Panos 15 Comments

Here’s your quick and dirty hack for the day. Sometimes you just need something that will work for what you’re trying to do, and you don’t want to go through the motions of doing what’s prescribed. When this happens, it’s a cheap, disposable tool that fits the bill. No, we’re not talking about Harbor Freight—we mean those need-driven tools you make yourself that get the job done without fuss. If you’re really lucky, you can use them a couple of times before they break.

This is one of those tools. [Jake’s Workshop] wanted to be able to quickly tack a corner weld without getting out the clamps, so he thought, why not print some magnet squares? [Jake] hollowed out the triangle to save filament, but this also gives it a nice advantage over store-bought magnet squares: instead of grasping and pulling it off, you can hook your finger through it and then hang it on the pegboard for next time.

[Jake] got lucky with the pocket sizes and was able to press fit the magnets in place, but it would be worth it to add a drop of CA glue to help with strain. He seems to have forgotten to upload the files for his various styles, but a hollow triangle with chamfers and magnet pockets should be easy enough to replicate in OpenSCAD or SolidWorks, which he used in the video below.

There’s something special about a cheap tool you make yourself. Even though you know it won’t last forever, it’s just more meaningful than some cheap, rage-inducing tchotchke or assemblage from a place where the air is ~85% offgasses. We love necessity-driven self-built tools around here so much that we gave them their own Hacklet.

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44 Layers Of Katharine Burr Blodgett

January 2, 2018 by Kristina Panos 22 Comments

Whether you realize it or not, Katharine Burr Blodgett has made your life better. If you’ve ever looked through a viewfinder, a telescope, or the windshield of a car, you’ve been face to face with her greatest achievement, non-reflective glass.

Katharine was a surface chemist for General Electric and a visionary engineer who discovered a way to make ordinary glass 99% transparent. Her invention enabled the low-cost production of nearly invisible panes and lenses for everything from picture frames and projectors to eyeglasses and spyglasses.

Katharine’s education and ingenuity along with her place in the zeitgeist led her into other fields throughout her career. When World War II erupted, GE shifted their focus to military applications. Katharine rolled up her sleeves and got down in the scientific trenches with the men of the Research Lab. She invented a method for de-icing airplane wings, engineered better gas masks, and created a more economical oil-based smokescreen. She was a versatile, insightful scientist who gave humanity a clearer view of the universe.

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Watch Video On A Oscilloscope With An ESP32

December 23, 2017 by Dan Maloney 18 Comments

[bitluni] got a brand new scope, and he couldn’t be happier. No, really — check the video below; he’s really happy. And to celebrate, he turned his scope into a vector display using an ESP32.

Using a scope in X-Y mode is nothing new, of course. The technique is used to display everything from Lissajous patterns from an SDR to bouncing balls from an analog computer. Taken on as more of an exercise to learn how to use his new tool than a practical project, [bitluni]’s project starts by using two DACs on an ESP32 to create simple Lissajous patterns to learn about the scope’s controls. Next he built some code to display 3D point clouds, but learned that the native DAC code wasn’t up to the job. A little hacking improved the speed 27-fold, which was enough for great 3D images and live video from an I²S camera module. The latter was accomplished by grabbing frames from the camera and rendering them pixel by pixel, CRT style. The results are pretty clean, and there’s a lot to be learned about both using scopes as X-Y displays and tweaking the ESP32 for maximum performance.

Need more background on the ESP32? Start by checking out these ESP32 tutorials.

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VFD Puts The Suck Back Into Desoldering Station

December 22, 2017 by Dan Maloney 19 Comments

A dedicated desoldering station is a fantastic tool if you’re in the business of harvesting components from old gear. Having heat and suction in a single tool is far more convenient than futzing with spring-loaded solder suckers or braid, but only as long as the suction in the desoldering tool has a little oomph behind it. So if the suction on your solder sucker is starting to suck, this simple VFD can help restore performance.

Luckily for [Mr. Carlson], his Hakko 470 desoldering station is equipped with an AC induction motor, so it’s a perfect candidate for a variable frequency drive to boost performance. He decided to build a simple VFD that boosts the frequency from 60-Hz mains to about 90-Hz, thereby jacking the motor speed up by 50%. The VFD is just a TL494 PWM chip gating the primary coil of a power transformer through a MOSFET. Duty cycle and frequency are set by trimmers, and the whole thing is housed in an old chassis attached to the Hakko via an anachronistic socket and plug from the vacuum tube days. That’s a nice touch, though, because the Hakko can be returned to stock operation by a simple bridging plug, and the video below shows the marked difference in motor speed both with and without the VFD plugged in.

We’ve marveled at [Mr. Carlson]’s instrument packed lab before and watched his insider’s tour of a vintage radio transmitter. Here’s hoping we get to see more of his hopped-up solder sucker in action soon.

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Logic Analyzer Pushes The Limits Of Miniaturization

December 22, 2017 by Dan Maloney 9 Comments

Careful not to sneeze while using this diminutive logic analyzer — you could send it flying across the bench.

Undertaken more for the challenge than as a practical bench tool, [Uwe Hermann]’s tiny logic analyzer is an object lesson on getting a usable circuit as small as possible. Sure, some sacrifices had to be made; it’s only an eight-channel instrument without any kind of input protection at all, and lacks niceties like an EEPROM. But that allows it to fit on a mere 11 x 11-mm fleck of PCB. That’s a pretty impressive feat of miniaturization, given that the Cypress microcontroller running the show is in QFN package that takes up 64-mm² all by itself. A micro-USB connector takes up much of the back side of the board and allows the analyzer to talk to sigrok, an open-source signal analysis suite.

Everything about the project is totally open, including the PCB files, so you can build your own if you feel up to the challenge. We’d strongly suggest you check out this primer on logic analyzers first, though, especially since it focuses on the capabilities of the sigrok suite.