Squishy Miter Saw Shroud Spares You The Sneezy Bits

April 7, 2024 by Sonya Vasquez 8 Comments

Let’s be honest. When it comes to operating miter saws, these tools kick dust out the back like a spray paint can. Most of us have accepted this quirk as-is, but not [Inspire Woodcraft] who’s on a mission to achieve near perfect dust collection. And he nearly has it. With a budget dust collection setup, he’s able to eliminate over 90% of the dust from his cuts, and others who’ve adopted his setup can vouch for his results.

The solution comes in two pieces. First, he focuses on creating a new dust shroud or “boot” for collecting dust through the vacuum hookup on the back of the saw. What’s key here is that this dust boot is made from squishy silicone, enabling it to flare outwards and spread out as the saw travels downward into the material. It’s clear that [Inspire Woodcraft] has gone through dozens of material and shape iterations, but the result is sturdy enough to stay open with the vacuum running through the back hose attachment.

With the dust nearly perfectly funneled from the back, the second tweak focuses on rerouting stray dust away from the table and directly into this boot. [Inspire Woodcraft] later noticed that dust collection from the bottom of his miter saw simply didn’t exist, so dust would accumulate at his feet.

His solution? To create a second shroud that fits under the throat plate that takes sawdust once destined for the ground and ejects it backwards and straight into the dust collection boot.

Altogether, this setup solves a long-existing problem with a handful of commodity parts and a few 3D prints. [Inspire Woodcraft] has also chronicled his journey in such detail where you too could recreate his solution from the video. But if you’re feeling lazy, and you’re lucky enough to own the same Dewalt DW716 or DWS716 model miter saws, you can simply snag a kit from his website.

If all this talk of miter saws has your reaching for a screwdriver to see what modified mayhem you can unleash with yours, look no further than this LED hack that adds a shadow line to your cuts.

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Comparing Desoldering Tools

April 7, 2024 by Al Williams 27 Comments

[Lee] has a Hakko FR301 desoldering gun and a Duratool knockoff. He freely admits that the Hakko is probably better, but he wonders if it’s good enough to justify being four times as expensive. He shows both of them off in a recent video that you can see below.

Often, desoldering doesn’t get as much attention as soldering, but for repairs or if you make mistakes — and who doesn’t — it is an essential skill. Many of the differences will be either good or bad, depending on your personal preference. For example, the Hakko is an all-in-one unit, so it doesn’t have a bulky box to sit on your bench. However, that also means the Hakko is larger and heavier. It also lacks controls and indicators the other unit has on the base station box.

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The line injector shown characterising the PSRR of an AMS1117 regulator, with a bunch of stuff connected to it through SMA jacks

A Simple Line Injector Shows You The Wonderful World Of PSRR

April 5, 2024 by Arya Voronova 8 Comments

[limpkin] writes us to show a line injector they’ve designed. The principle is simple — if you want to measure how much PSU noise any of your electronic devices let through, known as PSRR (Power Supply Rejection Ratio), you can induce PSU noise with this board, and then measure noise on your device’s output. The board is likewise simple. A few connectors, resistors, and caps, and a single N-FET!

You do need a VNA, but once you have that, you get a chance to peek into an entire world of insights. Does that 1117 LDO actually filter out noise better than a buck regulator? Is it enough to use a Pi filter for that STM32’s ADC rail, and do the actual parts you’re using actually help with that task? How much noise does your device actually let through in the real world, after being assembled with the specific components you’ve picked? [limpkin] shows us a whole bunch of examples – putting regulators, filters and amplifiers to the test, and showing us how there’s more than meets the eye.

Everything is open source, with full files available on the blog. And, if you want it pre-assembled, tested and equipped with the CNC-milled case, you can get it on Tindie or Lektronz! Of course, even without a tool like this, you can still get good filter designs done with help of computer-aided modelling.

We thank [alfonso] for sharing this with us!

Vibratory Rock Tumbler Bounces On Printed Spring

April 4, 2024 by Tom Nardi 27 Comments

If you’re reading Hackaday, there’s a good chance you had a rock tumbler in your younger days. Hell, we’d put odds on a few of you having one rumbling away in the background as you read this. They’re relatively simple contraptions, and a common enough DIY project. But even still, this largely 3D printed rock tumbler from [Fraens] is unique enough to stand out.

To make a basic rock tumbler, all you really need to do is rotate a cylindrical chamber and let physics do its thing. Such contraptions are known as, unsurprisingly, rotary rock tumblers. But what [Fraens] has put together here is a vibratory tumbler, which…well, it vibrates. If this was Rockaday we might go farther down this particular rabbit hole and explain the pros and cons of each machine, but the short version is that vibratory tumblers are more mechanically complex and are generally better suited to fine finish work than rotary tumblers which take a brute force approach that tends to round off the rocks.

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Showing the ESP-Prog-Adapter board plugged into the ESP-Prog adapter, wired to a SOIC clip, that then attaches to a PCB under test

ESP-Prog-Adapter Makes Your ESP32 Tinkering Seamless

April 3, 2024 by Arya Voronova 8 Comments

Did you ever struggle with an ESP32 board of yours, wishing you had exposed that UART, or seriously lacking the JTAG port access? If so, you should seriously check out [0xjmux]’s ESP-PROG-Adapter project, because [0xjmux] has put a lot of love and care into making your ESP32 hardware interfacing a breeze. This project shows you how to add JTAG and UART headers with extra low board footprint impact, gives you a KiCad library to do so super quickly, and shares a simple and helpful adapter PCB you can directly use with the exceptionally cheap Espressif’s ESP-Prog dongle you should have bought months ago.

The hardware is perfect for ZIF no-soldering interfacing – first of all, both UART and JTAG can be connected through a SOICBite connection, a solderless connector idea that lets you use SPI flashing clips on specially designed pads at the edge of your board. For the fancy toolkit hackers among us, there’s also a Tag Connect symbol suggested and a connector available, but it carries JTAG that you will already get with the SOICBite, so it’s maybe not worth spending extra money on.

Everything is fully open-source, as one could hope! If you’re doing ESP32 hacking, you simply have to order this board and a SOIC clip to go with it, given just how much trouble [0xjmux]’s board will save you when programming or debugging your ESP32 devices. Now, you don’t strictly need the ESP-Prog dongle – you could remix this into an adapter for the Pi Pico board instead. Oh, and if designing boards with ARM CPUs are your thing, you might benefit from being reminded about the Debug Edge standard!

Multiply Your Multimeter With Relays And USB

April 2, 2024 by Dan Maloney 10 Comments

Multimeters are a bit like potato chips: you can’t have just one. But they’re a lot more expensive than potato chips, especially the good ones, and while it’s tempting to just go get another one when you need to make multiple measurements, sometimes it’s not practical. That’s why something like this 2×4 relay-based multiplexer might be a handy addition to your bench

In this age of electronics plenty, you’d think that a simple USB relay board would be easy enough to lay hands on. But [Petteri Aimonen] had enough trouble finding a decent one that it became easier to just roll one up from scratch. His goal was to switch both the positive and negative test leads from up to four instruments to a common set of outputs, and to have two independent switching banks, for those times when four-lead measurements are needed. The choice of relay was important; [Petteri] settled on a Panasonic DPDT signal relay with low wetting current contacts and a low-current coil. The coils are driven by a TBD62783A 8-channel driver chip, while an STM32 takes care of USB duties.

The mechanical design of this multiplexer is just as slick as the electrical. [Petteri] designed the PCB to act as the cover for a standard Hammond project box, so all the traces and SMD components are mounted on the back. That just leaves the forest of banana-plug binding posts on the front, along with a couple of pushbuttons for manual input switching and nicely silkscreened labels. The multiplexer is controlled over USB using the SCPI protocol, which happily includes an instrument class for signal switchers.

We think the fit and finish on this one is fantastic, as is usual with one of [Petteri]’s builds. You’ll probably recall his calibrated current reference or his snazzy differential probe.

Modular Vacuum Table Custom-Fits The Parts

March 31, 2024 by Donald Papp 3 Comments

[enhydra] needed to modify a bunch of side inserts from some cheap ABS enclosures, and to save time and effort, he created a simple vacuum table with swappable inserts to precisely fit the parts. Suction is provided by a shop vacuum (plugged in near the bottom in the photo above) and it worked very well! Sealing and gaskets weren’t even required.

A vacuum table provides a way to hold workpieces flat and secure while a CNC machine does its thing, and because no clamps are involved, it can really speed up repetitive work. [enhydra]’s solution combines a vacuum table with a jig that ensures every rectangular piece is held exactly where the machine expects it to be, making the whole process of modifying multiple units significantly more efficient.

The whole thing — vacuum table and modular top — was straightforward to CNC cut out of what looks like particle board and worked as-is, no added gaskets or seals required, making this a very economical solution.

Vacuum tables can be pretty versatile and applied in more than one way, so keep that in mind the next time you’re wondering how best to approach a workshop problem. We’ve seen a well-engineered table used to speed up PCB milling, and we’ve also seen a DIY vacuum table combined with a heat gun and plastic plates from the dollar store make a bare-bones thermoforming rig.