Hundred Dollar Capacitive Discharge Welder

August 1, 2012 by Brian Benchoff 40 Comments

[Robert] needed to weld metal tabs on a few batteries. In a proper manufacturing situation, this is usually done with outrageously expensive welders. Not wanting to spend thousands of dollars to attach bits of metal together, [Robert] built his own capacitive discharge welder for only $100.

Instead of the giant transformers you’d find in a spot welder, a capacitive discharge welder uses a huge bank of capacitors – greater than 1 Farad – to weld pieces of metal together. Huge caps like these are commonly used for ridiculous car stereo setups, so with the addition of a car battery charger purchased from Walmart, [Robert] had most of a welder on his workbench.

To control the mass of power coming from his huge cap, [Robert] used a 13o amp Silicon controlled rectifier to improve the control of his welder. With the battery charger, cap, and SCR, [Robert] only needed a few bits of heavy gauge wire to tie the entire build together.

[Robert]’s build welds metal tabs on battery terminals beautifully, but the possibilities don’t end there. This welder could easily be repurposed to build the skeleton of outrageously intricate dead bug circuits, or maybe even keeping that thing you made with your Erector set in one piece permanently.

Mouth-powered Tools That Will Make Your Dentist Cringe

July 31, 2012 by Mike Szczys 25 Comments

Want to try your luck drilling out a PCB with this mouth-powered drill? [Cheng Guo] shows off one of his many mouth-powered tools above. It’s a tiny drill which spins with the opening and closing of your jaw. The concept may seem a bit silly, but his ability to fabricate these machines is fantastic.

The clip after the break starts off with the drilling demo seen above. From there he shows off several different tools. One is a molding machine that uses your breathing to spin a mold, thereby forcing the material inside to conform to its shape. There’s also a wood lathe. You hold the cutting tool in the your mouth and spin the mechanism with a bow and string setup. If you’re good at sucking, his vacuum former is right up your alley. Just heat up the plastic stock in the microwave and suck with all your might. Finally he shows off an extruder. We’re not quite sure how that one works.

Continue reading “Mouth-powered Tools That Will Make Your Dentist Cringe” →

Giving An ATX Bench Supply The Case It Deserves

July 20, 2012 by Mike Szczys 31 Comments

Your bench supply doesn’t need to look sad just because you’re using an ATX power supply instead of a commercial product. Follow [Ian Lee’s] example and you could have beautiful wooden enclosures for the tools in your own shop.

The woodworking skills used here aren’t all that advanced, but you need to have a knack for it so we suggest running some test pieces before you start the actual build. [Ian] ran a dado for the front and back panel in each piece of the wood sides. At each corner the inside of the the pieces were mitered at 45 degrees. To put it all together he laid the pieces end to end on a the work bench, then applied painters tape to the outside of the joints. This holds the joints together so that he can flip the collection over, apply glue, and then start hinging the sides into place. It’s almost like rolling up a box.

As with other ATX supply projects we’ve seen [Ian] designed this so that the PSU can be swapped out later if necessary. Instead of wiring his own cable harness he used an ATX breakout board. To get the interface layout he wanted he mounted the banana jacks separately and just ran jumper cables back to that board.

Cutting Islands Into Copper-clad PCBs With A Drill

July 20, 2012 by Mike Nathan 18 Comments

If you’re looking to build some small radio circuits, or if you are simply seeking a new look for your PCBs, you might want to check out what YouTube user [AndyDaviesByTheSea] has been working on lately. He has been building RF circuits as of late and was searching for a better way to create islands or “lands” on copper-clad PCBs.

He says that these sorts of islands are traditionally cut into the PCB with a scalpel or file – hardly an efficient process. [Andy] did a little experimenting and found a great way to quickly and precisely cut lands with a drill. Borrowing a bit of metal from an old VHS tape, he crafted a circular land cutter with a metal file. When mounted as a drill bit, his cutter produces clean, shallow cuts which create perfect lands on which to solder his components.

The only drawback to this method is that [Andy] found his bits were being dulled by the fiberglass boards pretty quickly. His solution was to carefully grind a broken heavy duty drill bit to do the task, which he says works even better than his original cutter.

Repurposing Server PSU For Your Charging Needs

July 17, 2012 by Mike Szczys 21 Comments

That grey box at the top of the photo is a modular power supply unit for a rack-mounted server system. [Sebastian] decided to repurpose it as a charging source for his RC batteries. He chose this HP DPS-600PB because of its power rating, efficiency, and you can get them at a reasonable price.

This is an active power factor corrected (APFC) PSU, which he says draws 40% less current than the non-APFC variety. Since he sometimes charges batteries in the field from a generator this is a big plus. But a bit of modification is necessary before it can be used as a source.

Since this is a rack device it has a set of connectors on the back. For power there are spade connectors which mate with a fin on the rack. He soldered positive and negative leads between the spades to interface with the battery chargers. The PSU won’t fire up if it’s not in the rack, so some jumper wires also need to be added connecting three of the interface pins.

With his modding all worked out he went on to use two PSUs for a 24V source, housing them to a nice carrying case while at it.

Dealing With The Horrors Of PDFs By Binding Your Own Books

July 16, 2012 by Brian Benchoff 66 Comments

Looking at a few PDFs of data sheets, journal articles, or even complete books can be a pain. Not only do you have to deal with the torment of a PDF reader (we’re looking at you, Adobe), but a purely electronic document misses the beautiful tactile interface available in dead tree format. [samimy] put together an amazingly professional video showing us how to turn our convenient yet unwieldy PDFs into paperback books, perfect for a very accessible off-line reference.

[samimy]’s build is basically a few pieces of wood and C clamps designed to compress the printed PDF together. After drilling a few holes along the spine, he stitches the pages together with very strong thread and applies a little glue to the spine. After removing the pages from the press, [samimy] applied a piece of tape to the spine and had a very nice looking paperback book.

While [samimy] is using his binding jig for data sheets, we see no reason why a more prodigious tome couldn’t be created with his rig. A few pages of marbled paper and a leather cover would result in a beautiful and functional work of art that will be around long after you’re gone.

Android Oscilloscope Built From Parts Just Lying Around

July 14, 2012 by Brian Benchoff 36 Comments

So you need to debug a circuit and you don’t have an oscilloscope. That’s not a problem thanks to [retronics] $0 Android oscilloscope, made with parts he just happened to have lying around.

The heart of every modern oscilloscope is the ADC – the chip that takes analog input and outputs a digital signal. Every Android device has one of these converters connected to the microphone port. All [retronics] needed to do was solder up a 3mm headphone jack, wire in a few resistors, and attach a pair of alligator clips. After installing an oscilloscope app, [retronics] had a half decent ‘scope.

Yes, this is truly a poor man’s oscilloscope, and [retronics] probably won’t be debugging high frequency RF circuits with his Android microphone jack anytime soon. Low frequency stuff such as audio is where this ‘scope really excels; even more so if a small preamp is thrown into the mix.

You can check out [retronics]’ build after the break. Sure, it’s not something for precise and calibrated measurement, but sometimes you only need a tool that will do the job.

Continue reading “Android Oscilloscope Built From Parts Just Lying Around” →