Tool Hacks

2908 Articles

Homemade SawStop Attachment Is Just About As Sketchy As It Sounds

August 2, 2022 by 56 Comments

TL;DR — when [Colin Furze] is your “safety inspector,” you really should be reconsidering your project goals.

Most of us have probably by now seen the SawStop brand of self-stopping table saw, which detects when something meatier than wood has the bad taste to touch the spinning blade, more or less instantly stopping it and preventing sudden traumatic amputations. It’s an outstanding idea, and we’d love to see the technology built into all table saws. But alas, SawStop saws are priced out of reach for many woodworkers, which left [Ruth Amos] to roll her own DIY version of the system.

It should be stated right off the bat that none of what [Ruth] does here is a good idea, and that everything shown is really just a proof of concept. The basis for her build was a somewhat flimsy-looking contractor-style saw, to which [Ruth] attached an Arduino set up to detect when something conductive touches the blade. She shares no particulars on the sensing method, but our guess is capacitive coupling. She then sets about experimenting with a series of above-table gizmos to arrest the blade, with limited success, plus all the attachments would make the saw essentially useless. But working above the table does make sense in the prototyping phase, and allowed her to figure out what wouldn’t work.

In the end, it was an electromagnetic clutch from an electric lawnmower that seemed to do the trick, albeit at the expense of heavy mods to the saw and a considerable increase in the system’s angular momentum. Nonetheless, the blade stops pretty close to instantly in the old hot dog test. It doesn’t drop the blade below the table, of course, and the hot dog is a little worse for the wear, but it’s still pretty impressive.

We’ve discussed SawStop’s technology before and why it isn’t perhaps as widely available as it should be, if you’re curious.

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OpenDendrometer Can Measure How Your Tree Feels

August 1, 2022 by 12 Comments

There are various ways to measure plant health, and we’ve seen many projects creating open-source solutions. One we haven’t seen is a dendrometer, which involves measuring various physical dimensions of trees to track their health and growth. [John Opsahl] is changing this with the OpenDendrometer, a tool for tracking the diameter of tree limbs and fruit.

Tiny changes in diameter take place throughout the day, and tracking these changes allows deviations to be detected, which can be a sign of water stress. Over weeks and months, these measurements can be used to measure growth and fruits’ progress to harvest. [John] found that a digital tire tread depth gauge can work well for this application. Many of these gauges use the same electronics as the cheap digital calipers, for which the serial protocol was reverse engineered more than a decade ago. The OpenDendrometer connects the tire depth gauge to a microcontroller via a 1.5V level shifter, which logs measurements to an SD card while using a DS3231 RTC for accurate timestamps. The RTC can also be used to wake up the circuit at the required intervals to save battery power. For the initial proof of concept [John] is using an Arduino Pro Mini, but plans to move to an ESP32 at a later stage to allow wireless data transmission.

Everything will be housed in a 3D printed enclosure with a foam cord gasket to make the device weather resistant. A mounting rod on the outside of the enclosure with adjustable thumbscrews allows the OpenDendrometer to be attached to any part of the tree. We plan to keep an eye on this project and look forward to seeing the data it produces.

For the other ways of measuring plant health, we’ve covered everything from soil moisture to Normalized Difference Vegetation Index and even plant weight and even pot plant weight.

Digital Measuring Wheel Is Exactly What It Sounds Like

July 23, 2022 by 11 Comments

You may have seen surveyors (or maths students) running around with measuring wheels, counting the clicks to measure distances. [AGBarber]’s digital measuring wheel works in much the same way, but with the convenience of a measurement you can read off a screen.

The design is simple, and relies on the outer wheel of the device turning a mouse encoder wheel. This is read by anArduino Pro Mini which runs the show and records the requisite measurements. It then drives an SSD1306 OLED display which shows the measurements to the user. It’s all wrapped up in a 3D printed housing that makes it easy to roll around the small handheld device.

The wheel’s maximum measuring length is 9999.99 cm, or just under 100 meters. Given the size of the device, that’s probably more than enough, but you could always build a bigger version if you wanted to measure longer distances.

Measuring wheels make it easy to measure along curves, and are just generally fun to play with as well. You could certainly use one to determine whether flat tyres are making your speedometer lie to you. Or, you could dive into this great talk on measurement from [Adam Savage].

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Homebrew Curve Tracer Competes With The Big Guns

July 22, 2022 by 22 Comments

When we first saw the VBA curve tracer, we thought it might have something to do with Visual Basic for Applications. But it turns out it is a mash up of the names of the creators: [Paul Versteeg], [Bud Bennett], and [Mark Allie]. [Paul] designed an original prototype back in 2017. Since then, the project has grown and lessons were learned. The final curve tracer is pretty impressive in more ways than one.

If you’ve never used a curve tracer, they allow you to characterize components using their characteristic curve of voltage versus current. You use an oscilloscope as an output device. This instrument is often used by engineers trying to understand or match devices like diodes, transistors, or — in some cases — even tubes. So if you want to measure the collector-emitter breakdown voltage, for example, or the collector cutoff current, this is your go-to device. You can also match gains in circuits where that matters (for example, a push-pull circuit where two transistors amplify different parts of the same signal).

If you want to understand more about how it works, there are a series of blog posts covering the evolution of the device. You can also find the design files on GitHub. There is also a handy post showing many types of measurements you might want to make.

This is a good-looking project. We’ve seen it done on the cheap, but slowly. Or spend $15 and do better. We doubt any of these have high enough voltages to do most tubes, but they made the same basic instrument for tubes back in the 1950s.

Cut Just About Anything With This Combination Lathe And Wire EDM

July 20, 2022 by 18 Comments

They say that if you have a lathe, you have every other machine tool too. To some degree, that’s true — you can make almost anything on a lathe, including another lathe, and even parts best made on other machine tools can usually be made on a lathe in a pinch. But after seeing this lathe attachment for a DIY electric discharge machining tool, we might be inclined to see the EDM as the one machine tool to rule them all.

Now, we’ll admit that the job [BAXEDM] built this tool for might be a little contrived. He wanted to make some custom hex inserts for his Swiss Army knife, which seem like they’d have been pretty easy to make from hex bar stock in a conventional lathe. Then again, hardened steel is the kind of material that wire EDM was made for, and there seem to be many use cases for an attachment that can spin a workpiece against an EDM cutting wire.

That was really the trick of this build — spinning a part underwater. To accomplish this, [BAXEDM] built a platform to carry a bearing block that supports a standard ER-25 collet, with a bracket that holds a stepper clear of the water in the EDM cutting tank. There are plenty of 3D printed insulators too, to keep most of the attachment electrically isolated from the EDM current, plus exotic parts like ceramic bearings that won’t corrode under water. There were a ton of other considerations, too; [BAXEDM] goes through the long iterative design process in the video below, as well as taking his new tool for a literal spin starting at about the 27:00 mark.

If you’re intrigued by what EDM can accomplish — and who wouldn’t be? — but you need more background on the process, we’ve got you covered.

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Programmable Resistance Box

July 19, 2022 by 32 Comments

For prototype electronics projects, most of us have a pile of resistors of various values stored somewhere on our tool bench. There are different methods of organizing them for easy access and identification, but for true efficiency a resistance substitution box can be used on the breadboard to quickly change resistance values at a single point in a circuit. Until now it seemed this would be the pinnacle of quickly selecting differently-sized resistors, but thanks to this programmable resistor bank there’s an even better option available now.

Unlike a traditional substitution box or decade box, which uses switches or dials to select different valued resistors across a set of terminals, this one is programmable and uses a series of sealed relays instead. That’s not where the features stop, though. It also comes equipped with internal calibration circuitry which take into account the resistance of the relay contacts and internal wiring to provide a very precise resistance value across its terminals. It’s also able to be calibrated manually to account for temperature or other factors.

For an often-overlooked piece of test equipment, this one surely fits the bill of something we didn’t know we needed until now. Even though digital resistor substitution boxes are things we have featured in the past, the connectivity and calibration capabilities of this one make it intriguing.

Putting A Cheap Laser Rangefinder Through Its Paces

July 19, 2022 by 18 Comments

Sometimes a gizmo seems too cheap to be true. You know there’s just no way it’ll work as advertised — but sometimes it’s fun to find out. Thankfully, if that gadget happens to be a MILESEEY PF210 Hunting Laser Rangefinder, [Phil] has got you covered. He recently got his hands on one (for less than 100 euros, which is wild for a laser rangefinder) and decided to see just how useful it actually was.

The instrument in question measures distances via the time-of-flight method; it bounces a laser pulse off of some distant (or not-so-distant) object and measures how long the pulse takes to return. Using the speed of light, it can calculate the distance the pulse has traveled).

As it turns out, it worked surprisingly well. [Phil] decided to focus his analysis on accuracy and precision, arguably the most important features you’d look for while purchasing such an instrument. We won’t get into the statistical nitty-gritty here, but suffice it to say that [Phil] did his homework. To evaluate the instrument’s precision, he took ten measurements against each of ten different targets of various ranges between 2.9 m and 800 m. He found that it was incredibly precise (almost perfectly repeatable) at low distances, and still pretty darn good way out at 800 m (±1 m repeatability).

To test the accuracy, he took a series of measurements and compared them against their known values (pretty straightforward, right?). He found that the instrument was accurate to within a maximum of 3% (but was usually even better than that).

While this may not be groundbreaking science, it’s really nice to be reminded that sometimes a cheap instrument will do the job, and we love that there are dedicated folks like [Phil] out there who are willing to put the time in to prove it.