Tool Hacks

3061 Articles

New Wisdom On Old Practices

March 31, 2017 by 14 Comments

Getting into machining is hard. From high-speed seel versus carbide to “old US iron” versus “new Asian manufacture” to simply choosing which drill bits to buy, many hard decisions must be made before one even has a chance to gain experience. Fear not, [Quinn Dunki] has created “a roadmap for how to get involved in this hobby.”

We saw [Quinn’s] first entry in her lathe series back in January, and now the series is complete! Starting with the definition of a machine tool and ending with the famous Clickspring scriber and a multi-material pen, [Quinn] leaves no stone unturned. [Quinn’s] style contrasts with the likes of [ThisOldTony], [AvE] or [Clickspring], as she makes sure to include the gory details of everything, citing her dissatisfaction with most YouTube machinists as motivation:

they’re all about the money shots of chips flying, but thin on the actual work of machining, which is mostly work-holding setups, changing bits and dies around, etc. That’s where all the knowledge is. The machine does the work once you spend 20 minutes setting it up properly for the operation. Everyone skips that part. I scour Tubalcain videos for details like the angle of the compound for a facing operation, or how to drill a deep hole with a short tail stock without the carriage getting in the way. Simple things like that get glossed over, but stump a beginner.

Of the series, our favorite part was “Grinding tool bits.” When combined with [ThisOldTony’s] Grinding HSS Tools, the two form an education in high-speed steel tool grinding fit for a hacker. Need more than high-speed steel? We’ve got you covered.

Make A PVC Drill Press

March 31, 2017 by 32 Comments

There are two types of people in this world: people who think that PVC is only suitable for plumbing, and people who don’t even know that you can use PVC to carry water. Instructables user [amjohnny] is clearly of the latter school. His PVC Dremel drill press is a bit of an oldie, but it’s still a testament to the pipefitter’s art. And you can watch it in action in the video embedded below.

Things we particularly like about this build include the PVC parallelogram movement, springs around tubes to push the Dremel head back up, and the clever use of a T-fitting and screw plug to hold the press in its lowest position. We wonder how one could add a depth stop to this thing. No matter, we love watching it work.

Anyway, this is just one hack of many that emphasizes the importance of a drill press in basically anyone’s life, as well as the ease of DIY’ing into one. If you’re in the PVC-haters camp, but have some scrap wood and drawer slides or plastic offcuts lying around, you have the makings of a rudimentary press — a welcome tool in the shop.

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Hackaday Prize Entry: A CNC Mill Without The C

March 30, 2017 by 17 Comments

It’s a staple of home CNC construction, the 3D mill built on the bench from available parts. Be the on a tubular, plywood, or extruded aluminum frame, we’ve seen an astonishing array of mills of varying levels of capability.

The norm for such a mill is to have a computer controlling it. Give it a CAD file, perform the software magic, press button, receive finished object (Or so the theory goes). It’s a surprise then to see a mill in which the input doesn’t come from a CAD file, instead all control is done by hand through the medium of a joystick. [Mark Miller]’s 3D printed freeform carving machine is a joystick-controlled mill with a rotary tool on an arm facing a rotatable bed, and it can perform impressive feats of carving in expanded foam.

You might ask why on earth you should make a machine such as this one when you could simply pick up a rotary tool in your hand and start carving. And you’d be right, from that perspective there’s an air of glorious uselessness to the machine. But to take that view misses the point entirely, it’s a clever build and rather a neat idea. We notice he’s not put up the files yet for other people to have a go, if someone else fancies making CNC software work with it then we’re sure that would be possible.

There is a video showing the basic movements the mill is capable of, which we’ve put below the break. Best to say, though, it’s one on which to enable YouTube’s double speed option.

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Casting Machine Bases In Composite Epoxy

March 27, 2017 by 62 Comments

When you’re building a machine that needs to be accurate, you need to give it a nice solid base. A good base can lend strength to the machine to ensure its motions are accurate, as well as aid in damping vibrations that would impede performance. The problem is, it can be difficult to find a material that is both stiff and strong, and also a good damper of vibrations. Steel? Very stiff, very strong, terrible damper. Rubber? Great damper, strength leaves something to be desired. [Adam Bender] wanted to something strong that also damped vibrations, so developed a composite epoxy machine base.

[Adam] first takes us through the theory, referring to a graph of common materials showing loss coefficient plotted against stiffness. Once the theory is understood, [Adam] sets out to create a composite material with the best of both worlds – combining an aluminium base for stiffness and strength, with epoxy composite as a damper. It’s here where [Adam] begins experimenting, mixing the epoxy with sand, gravel, iron oxide and dyes, trying to find a mixture that casts easily with a good surface finish and minimum porosity.

With a mixture chosen, it’s then a matter of assembling the final mould, coating with release agent, and pouring in the mixture. The final result is impressive and a testament to [Adam]’s experimental process.

We’ve seen similar builds before — like this precision CNC built with epoxy granite — but detail in the documentation here is phenomenal.

A Wireless Oscilloscope Isn’t As Dumb As It Sounds

March 18, 2017 by 38 Comments

The latest CrowdSupply campaign is a wireless, Bluetooth oscilloscope that doesn’t make a whole lot of sense until you really think about it. Once you get it, the Aeroscope wireless oscilloscope is actually a pretty neat idea.

If the idea of battery-powered, Bluetooth-enabled test and measurement gear sounds familiar, you’re not dreaming. The Mooshimeter, also a project on CrowdSupply, is a multichannel multimeter with no buttons, no dial, and no display. You use the Mooshimeter through an app on your phone. This sounds like a dumb idea initially, but if you want to measure the current consumption of a drone, or under the hood of your car while you’re driving, it’s a really, really great idea.

The specs of the Aeroscope aren’t bad for the price. It is, of course, a one-channel scope with 20 MHz bandwidth and 100Msps. Connection to the device under test is through pokey bits or grabby bits that screw into an SMA connector, and connection to a display is over Bluetooth 4.0. You’re not getting a scope that costs as much as a car here, but you wouldn’t want to put that scope in the engine bay of your car, either.

The Aeroscope is currently on CrowdSupply for $200. Compared to the alternatives, that’s a bit more than the no-name, USB scopes. Then again, those are USB scopes, not a wireless, Bluetooth-enabled tool, and we can’t wait to see what kind of work this thing enables.

Electric Arc Furnace Closes The Loop

March 17, 2017 by 21 Comments

When we think of an Electric Arc Furnace (EAF), the image that comes to mind is one of a huge machine devouring megawatts of electricity while turning recycled metal into liquid. [Gregory Hildstrom] did some work to shrink one of those machines down to a practical home version. [Greg] is building on work done by [Grant Thompson], aka “The King of Random” and AvE. Industrial EAFs are computer controlled devices, carefully lowering a consumable carbon electrode into the steel melt. This machine brings those features to the home gamer.

[Greg] started by TIG welding up an aluminum frame. There isn’t a whole lot of force on the Z-axis of the arc furnace, so he used a stepper and lead screw arrangement similar to those used in 3D printers. An Adafruit stepper motor shield sits on an Arduino Uno to control the beast. The Arduino reads the voltage across the arc and adjusts the electrode height accordingly.

The arc behind this arc furnace comes from a 240 volt welder. That’s where [Greg] ran into some trouble. Welders are rated by their duty cycle. Duty cycle is the percentage of time they can continuously weld during a ten minute period. A 30% duty cycle welder can only weld for three minutes before needing seven minutes of cooling time. An electric arc furnace requires a 100% duty cycle welder, as melting a few pounds of steel takes time. [Greg] went through a few different welder models before he found one which could handle the stress.

In the end [Greg] was able to melt and boil a few pounds of steel before the main 240 V breaker on his house overheated and popped. The arc furnace might be asking a bit much of household grade electrical equipment.

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Roam The Wastelands With This Fallout-Themed Mini Geiger Counter

March 16, 2017 by 46 Comments

For anyone who has worked with radioactive materials, there’s something that’s oddly comforting about the random clicks of a Geiger counter. And those comforting clicks are exactly why we like this simple pocket Geiger counter.

Another good reason to like [Tim]’s build is the Fallout theme of the case. While not an item from the game, the aesthetic he went for with the 3D-printed case certainly matches the Fallout universe. The counter itself is based on the popular Russian SBT-11A G-M tubes that are floating around eBay these days. You might recall them from coverage of this minimalist Geiger counter, and if you were inspired to buy a few of the tubes, here’s your chance for a more polished build. The case is stuffed with a LiPo pack, HV supply, and a small audio amp to drive the speaker. The video below shows it clicking merrily from a calibration source.

We can see how this project could be easily expanded — a small display that can show the counts per minute would be a great addition. But there’s something about how pocketable this is, and just the clicking alone is enough for us.

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