Wooden Band Saw Fears Its Wood-Cutting Brethren

June 22, 2014 by Rich Bremer 18 Comments

DIY Wooden Bandsaw

What is cooler than building a band saw out of wood? Building two, of course! And that is exactly what [Pekka] did. The first was a small bench top model while the second was a much larger version with the saw blade strung between big 13-3/4 inch wheels. For those who are unfamiliar with band saws, they are tools that have a long thin blade that is routed around rotating wheels. The wheels are spread apart to make the blade taut. Unlike the reciprocating action of a jigsaw, saws-all or scroll saw, the band saw blade continually rotates in one direction. These blades are typically thin making it easy to cut irregular and curved shapes.

The frame of [Pekka’s] larger machine is made from 35mm (~1-3/8″) plywood. This proved to be a sturdy frame material. The previously mentioned wheels were made by gluing pieces of oak together, mounting the assembly on a wood lathe and turning the outer diameter down to size. By using multiple piece of wood to construct the wheels allows the grain direction of each portion to be parallel with the blade. This method of construction ensures any expansion/contraction of the wood is uniform around the wheel. A strip of rubber around the blade’s outer diameter provides the friction required to prevent the blade from slipping.

[Pekka’s] friend was nice enough to turn the flanged axle shafts on his metal lathe. These shafts support the wooded wheels and are mounted in pillow block bearings. The upper pillow blocks are mounted to a sliding support that allows adjusting the tension of the saw blade. [Pekka] was not going to be satisfied with a one-speed band saw so he grabbed a motor he had kicking around that originally came from a wood lathe and already had 4 different sized pulleys mounted on the shaft.

This is a great project that shows what can be done with a little desire and ingenuity.

Clever Re-purposing Of A Power Drill Results In A Mini Wood Lathe

June 19, 2014 by James Hobson 25 Comments

Power Drill Wood Lathe

Ever use a lathe? No? Neither had [Jack Hauweling], but that didn’t stop him from building his own and learning how!

Lathes are a lot of fun, especially for small wood working projects. Using mostly wood and a few small pieces of hardware, [Jack] was able to build one in an afternoon that works quite well!

He’s using a cheap corded power drill to drive the work piece, but what we really like is how he made the spur center and spur live center out of a few pieces of threaded rod and a standoff. It’s a simple system that lets him secure the work piece fairly easily simply by tightening the threaded shaft of the live center.

In the video after the break he goes through the entire build process and even shows off his first attempts at using the lathe — he actually was able to make a very nice tool grip on his third try!

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The Analog Swiss Army Knife

June 19, 2014 by Brian Benchoff 33 Comments

11300

While FPGAs get all the credit for being the hip new thing, they are inherently digital devices. Without a proper ADC and DAC, you won’t be delving into the analog domain with your programmable logic. Maxim has just put out a chip that does just that: an analog swiss army knife with 20 pins that are configurable as analog to digital converter, digital to analog converters, GPIO, or any mix of the above.

The MAX11300 includes twenty IO ports, each capable of becoming an ADC, DAC, or GPIO, with pairs of ports capable of being configured as a logic level translator or an analog switch. The ADCs and DACs are 12-bit, with input and output ranges from -10V to +10V.

As a nice little bonus, the chip is controlled over SPI, making this an interesting device for a small “do anything analog” tool we’re sure will hit Tindie or Seeed Studio before the year is out. Luckily for whoever would create such a device, Maxim has a nice GUI for configuring each of the 20 pins on their chip, Of course Maxim already offers an evaluation kit for the MAX11300. It’s $100 USD and is Windows only.

The MAX11300 is available in either 40-pin TQFN or 48-pin TQFP packages (with the larger, easier to solder TQFP shipping later) for about $5.80 USD in quantity 1000, or $11.37 in quantity one.Video below showing off the MAX11300 reading and writing analog values to a few pins, and a good look at the configuration software.

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Miter Saw Stop Saves Time And Aggravation

June 19, 2014 by Rich Bremer 26 Comments

V Wheel Adjustable Miter Saw Stop

Miter saws are great tools for cutting pieces of wood at a variety of angles. If you have ever cut a really long piece on a miter saw there is no doubt you’ve either propped up the extended end on a pile of scrap wood or asked someone to hold the dangling piece so you could get an accurate cut. Doing either is a little hokey and is a general pain in the butt.

[Kram242] started a project that could eliminate these problems and also provides a solution to consistent length cuts of multiple pieces. It’s an adjustable stop that is sure to make miter saw cuts much less annoying.

The rig is extremely simple and consists of a piece of aluminum extrusion, v-wheel carriage and lever-actuated clamp. The movable carriage lets the operator quickly position the stop to ensure the wood is cut at the appropriate location. This stop also makes it easy to cut several pieces of wood to the exact same length.

If we had to make any suggestions for improvements it would be to add supports to the carriage that emulate the saw bed and backstop as well as an adhesive measuring tape guide.

V Wheel Adjustable Miter Saw Stop

I2C From Your VGA Port

June 18, 2014 by Eric Evenchick 38 Comments

VGA, DVI, and HDMI ports use Display Data Channel (DDC) to communicate with connected displays. This allows displays to be plug and play. However, DDC is based on I2C, which is used in all kinds of electronics. To take advantage of this I2C port on nearly every computer, [Josef] built a VGA to I2C breakout.

This breakout is based on an older article about building a $0.25 I2C adapter. This adapter hijacks specific lines from the video port, and convinces the kernel it’s a standard I2C device. Once this is done, applications such as i2c-tools can be used to interact with the port.

[Josef] decided to go for overkill with this project. By putting an ATmega328 on the board, control for GPIOs and LEDs could be added. Level shifters for I2C were added so it can be used with lower voltage devices. The end product is an I2C adapter, GPIOs, and LEDs that can be controlled directly from the Linux kernel through an unused video port.

Reflow Oven Controller With Graphic LCD

June 16, 2014 by Nick Conn 32 Comments

Reflow Controller

A reflow oven is one of the most useful tools you will ever have, and if you haven’t built one yet, now is as good a time as any. [0xPIT’s] Arduino based reflow oven controller with a graphic LCD is one of the nicest reflow controllers we’ve seen.

Having a reflow oven opens up a world of possibilities. All of those impossible to solder surface mount devices are now easier than ever. Built around the Arduino Pro Micro and an Adafruit TFT color LCD, this project is very straight forward. You can either make your own controller PCB, or use [0xPIT’s] design. His design is built around two solid state relays, one for the heating elements and one for the convection fan. “The software uses PID control of the heater and fan output for improved temperature stability.” The project write-up is also on github, so be sure to scroll down and take a look at the README.

All you need to do is build any of the laser cutters and pick and place machines that we have featured over the years, and you too can have a complete surface mount assembly line!

The Relay-Based Mouse Emulator

June 15, 2014 by Brian Benchoff 28 Comments

mouse

[Nixie]’s job involves using some test software that requires moving a mouse around, clicking a few buttons, checking if everything is okay, and repeating the process over and over again. This is obviously a solution for some keyboard macros, but in a fit of sadistic spite, the test software requires someone to move a mouse around the screen. What is [Nixie] to do? Make a mouse emulator and automate the whole thing, of course.

The Memulator, as [Nixie] calls the device, is the latest in a series of devices to increase productivity when testing. The first version was the mouse tumor, an odd-looking device that simply switched off the LED for an optical mouse, keeping the cursor in one spot while [Nixie] hammered a button repeatedly. The second version is more advanced, capable of moving the cursor around the screen, all without doing an iota of USB programming: [Nixie] is simply using a resistive touch pad, some relays and a few pots to turn buttons into cursor movements. It’s such a simple solution it almost feels wrong.

There’s some interesting tech here, nonetheless. For some reason, [Nixie] has a few cases of old, can-shaped soviet-era relays in this build. While using such cool, awesome old components in such a useful and productive build seems odd, if you’re trying to fix ancient software that’s so obviously broken, you might as well go whole hog and build something that will make someone in twenty years scratch their head.

Vertical video of the Memulator below.

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