Building A Tool To Bend Small Metal Tubes

January 21, 2013 by Brian Benchoff 32 Comments

tube

[Joel] is setting up a really nice workshop. Included in his list of machinery are the staples of any workshop; a lathe, miter saw, containers full of organized screws, and a manual mill converted to a CNC machine. [Joel] wanted an oiling system for his mill, and like any good maker decided to fabricate his own. This required bending very small diameter brass tubes, something doable by hand (or without sand, at least). He decided to solve this problem with a DIY tube bending tool that allows him to bend tiny brass tubing without the walls collapsing.

[Joel] broke out his lathe and machined two brass rollers with a groove to hold his 3/16″ tubing. One of these brass rollers is attached to a handle, while the other is attached to a block that gets clamped into [Joel]’s bench vise. After threading some tubing through the rollers, [Joel] is able to bend it precisely with only a tiny bit of collapsing on small-radius bends.

Renaming Parts In Eagle CAD By Editing The XML Directly

January 18, 2013 by Mike Szczys 17 Comments

eagle-xml-find-and-replace-script

There’s a lot of ways to burn up your time when designing PCBs, but renaming components can be one of the most frustrating. [Joe Pinzone] wrote in with his solution to the problem. Instead of hunting for each part on the schematic to change them one at a time, he makes a list of the substitutions and then uses a script to make all the changes in the XML files. He didn’t publish a post about his work, but you’ll find the source code he wrote embedded after the break.

The straw that finally broke the camel’s back was a project that included about two hundred components which didn’t seem to have a naming order that made any sense with the actual values of the components. The script is written in C++ (for Windows but [Joe] says this should be easily ported to other systems as well). To use it he creates a CSV file with the current component names in the first column. He then goes through and types what he wants for the new name in the second column. This CSV, along with the BRD and SCH files are then given as inputs for the script (through selecting them all and dragging to the script or as CLI arguments) and it automatically makes the changes.

Of course this is only possible because Cadsoft transitioned to using XML files in Eagle 6.

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Kitchen Scale Key Transplant

January 14, 2013 by Mike Szczys 7 Comments

kitchen-scale-key-transplant

[Markus] is quite happy with his kitchen scale. It’s one of the tools he uses most frequently when cooking. But recently the button has begun to give him problems. He figures the years of spilling a little bit of this and that has mucked up the contacts. His solution was to bypass the button using a Cherry MX switch.

Really any replacement should do since the switch merely completes an electrical connection. But there’s a subset of hackers who swear by the Cherry MX switches that come in some keyboards. [Markus] had just such a keyboard on hand, which he was already using for parts, so he pulled out the switch and cut a hole in the scale’s case where he could mount it. After temporarily super gluing the switch in place he completed the task by filling the gap on the outside with hot glue, then running another bead of it along the inside. The addition of the ‘T’ key finishes the hack. The plastic key is easy to clean and will help shed flour, oil, or anything else he might spill during his culinary adventures.

This hack was fast and easy and may have convinced [Markus] to roll his own controller board for the device. We’ll keep a lookout for a follow-up post detailing those alterations.

Letting [Euler] Help Out With PCB Fabrication

January 11, 2013 by Brian Benchoff 20 Comments

drillin

Since [Alessio] has been etching his own PCBs, he’s hit upon the most tedious part of the process, and the reason homebrew SMD boards are so awesome: drilling your own boards is a pain. While [Alessio]’s CNC mill takes care of most of the work, aligning the pre-drilled boards and correcting for any scaling issues from the mask is a bit difficult. With the help of a transform matrix, though, drilling PCBs has never been easier.

While the Gcode running the mill may be accurate, the actual manufactured PCBs might not be. If the extents on [Alessio]’s board aren’t exactly aligned with the axes of the CNC mill, the drill holes end up where they’re supposed to be. To solve this problem, [Alessio] wrote a PCB drilling transformational matrix calculator. The basic idea is by drilling just a few holes, [Alessio] is able to calculate any offset required in the Gcode with the help of a little bit of linear algebra.

Motorized Binocular Chair Has You Stargazing In Comfort

January 10, 2013 by Mike Szczys 30 Comments

motorized-binocular-chair-for-stargazing-in-comfort

It seems like something out of The Red Green Show but this motorized stargazing chair is a serious piece of astronomical hardware. It has a shelf that places a set of high-power binoculars directly in the user’s line of sight. The elevation is easy to adjust. And a power drill lets you take the whole thing for a spin.

The base has been outfitted with cogs and a chain from an old bicycle. The gear reduction lets a power drill rotate the platform. This worked well enough but [Gary] found that making fine adjustments was rather difficult and more often than not he ended up moving the binoculars to avoid overshooting when adjusting the platform with the drill. Luckily he didn’t give up on the idea. On the eighth and final page of his build log he refines the rotating setup with the help of an ice cream maker. It’s gear box is used as a speed reducer so that a very slow drill speed results in an extremely small heading correction. Now he can view the stars in peace, freed from frustration by a well-refined hack.

Web-based TI Graphing Calculator Emulator

January 3, 2013 by Mike Szczys 39 Comments

You can leave the TI graphing calculator at home thanks to this web-based TI-83 and TI-84 emulator. As with pretty much all emulators, this depends on a ROM image from the actual hardware to work. But if you have one of the supported calculators (TI-83+, TI-83+ SE, TI-84+, or TI-84+SE) you can dump the image yourself and this should work like a charm.

[Christopher Mitchell] calls the project jsTIfied because he wrote it in JavaScript and HTML5 (that’s where the js comes from) and it’s based on the Texas Instruments line of hardware (hence the capital TI). After agreeing that you’re not getting any ROMs from his site you can choose the file to load on your browser. The image of the calculator has working buttons and will show the boot screen just like the real thing. You can use it like normal but you can load load up programs for the environment. See this demonstrated after the break.

We’ve seen some arguments online about the price of the TI line over the years. Prices haven’t dropped much over the decades even though they’re making pretty much the same hardware. It’s cool to see someone figure out how to emulate the hardware — and on a web interface to boot! But we’re left wondering why TI isn’t selling an equivalent app for iOS and Android or at least leveraging what must be millions in each production run for a lower retail price?

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Make Your Own Plastic Friction Welder

December 31, 2012 by Mike Szczys 63 Comments

[Fran] shows us how to build a plastic friction welder. It’s a method of connecting plastic pieces. While it’s new to us, apparently this type of tool was given to kids about forty years ago to use with craft project (when plastic was all the craze).

The tip of the friction welder is a styrene rod. If it’s spun fast enough the friction will cause the material to heat to the melting point, depositing a bead of styrene into the joint. The tool seen here is a cheap DC rotary tool acquired from Harbor Freight. It really did a horrible job, but [Fran] discovered that it was the power supply that was under-rated. When she replace the wire that feeds it and used her bench supply it spit out 16,000 rpm without any trouble. The welding rods can be found at the craft store and fit the chuck of the tool quite nicely. You can see her demo in the video after the break. The seam she’s working on comes out very strong, surviving a slew of violent whacks on the workbench.

We’ve seen a few other methods of welding plastic. One used a tool much like a soldering iron, the other depends on ultrasonic waves and clamping pressure.

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