Custom-Fit Small Shop Crane Lightens The Load

April 19, 2022 by Dan Maloney 13 Comments

On the shortlist of workshop luxuries, we’d bet a lot of hackers would include an overhead crane. Having the ability to lift heavy loads safely and easily opens up a world of new projects, and puts the shop into an entirely different class of capabilities.

As with many of us, [Jornt] works in a shop with significant space constraints, so the jib crane he built had to be a custom job. Fabricated completely from steel tube, the build started with fabricating a mast to support the crane and squeezing it into a small slot in some existing shelves in the shop, which somehow didn’t catch on fire despite being welded in situ. A lot of custom parts went into the slewing gear that mounts the jib, itself a stick-built space frame that had to accommodate a pitched ceiling. A double row of tubing along the bottom of the jib allows a trolley carrying a 500 kg electric winch to run along it, providing a work envelope that looks like it covers the majority of the shop. And hats off for the safety yellow and black paint job — very industrial.

From the look of the tests in the video below, the crane is more than up to the task of lifting engines and other heavy loads in the shop. That should prove handy if [Jornt] tackles another build like his no-compromises DIY lathe again.

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Gridfinity: 3D Printed Super Quick Tool Storage And Retrieval

April 18, 2022 by Dave Rowntree 32 Comments

Our favourite cyborg [Zack Freedman] has been stumbling over a common problem many of us will be all too familiar with — that of tool storage and the optimal retrieval thereof. His solution is the Gridfinity: A modular workshop organisation system.

Never chase your pen around on the desk again

In [Zack]’s words, the perfect workshop has tools and materials arranged in the following way: (a) every item has a dedicated home within reach of where you’ll use it. (b) items are exposed and in position for instant grabification. (c) the storage system shields you from accidents like spills and injuries. (d) it is effortless to setup and easy to put back and rearrange. An instant-access storage solution such as the Gridfinity is designed not to help you store more stuff, but finish more projects. The idea is very simple — display your stuff so that you can quickly find what you need and get back to the project as quickly as possible. We think these aims are pretty spot on!

From an implementation perspective, the system consists of a 3D printed base plate with a grid structure. It is angled internally so storage bins drop in, but are not easy to knock out. Storage units drop into the grid in various sizes and orientations, such that everything is contained within the grid’s outer boundary, so the whole assembly will fit inside a drawer with ease. Small part storage bins have a curved inner surface enabling one to easily scoop out a part when required. A partial lid on the top allows them to be stacked vertically if required.

Super-quick access to fully sorted stock – no more searching

Whilst the system is work in progress, there are still about a hundred different storage units, for anything from 3D printer nozzles to racks for tweezers. Implemented as parameterised models in Fusion360, it is easy to tweak existing models for your stuff, or create totally new ones, from the supplied templates.

No discussion of tool organisation would be complete without first considering the king of tool organisation [Adam Savage], the principle of first order retrieval is a strong one. For a more in-your-face solution, you could go down the pegboard-on-wheels route, or perhaps if you’re less mobile and in a tight squeeze, then get comfortable with the French cleat and build something full custom right into the walls. Whatever solution you come up with, do share it with us!

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An unfastened piece of pipe in a drill press, rotating away

Drill Press Piece Fastening 101

April 17, 2022 by Arya Voronova 16 Comments

What are the options you have for securing your workpiece to the drill press table? [Rex Krueger] shows us that there’s plenty, and you ought to know about them. He goes through the disadvantages of the usual C-clamps, and shows options like the regular drill press vice and a heavy-duty version that even provides a workpiece tilting mechanism, and points out small niceties like the V-grooves on the clamps helping work with round stock. For larger pieces, he recommends an underappreciated option — woodworkers’ wooden handscrew clamps, which pair surprisingly well with a drill press. Then, he talks about the hold-down drill press clamps, a favourite of his, especially when it comes to flat sheets of stock like sheet metal or plastic.

As a bonus for those of us dealing with round stock, he shows a V-block he’s made for drilling into its side, and round stock clamp, made by carefully drilling a pair of wooden hand screw clamps, for when you need to drill into a dowel from its top. The ten-minute video is a must watch for anyone not up to speed on their drill press piece fastening knowledge, and helps you improve your drilling game without having skin in it.

We’ve covered a few ingenious and unconventional drill piece fastening options before, from this wise held down by repurposed bicycle quick-release parts, to an electromagnetic wise that left our readers with mixed opinions.

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A handheld device to measure electromagnetic fields

Measuring Electromagnetic Fields With Just An Arduino And A Piece Of Wire

April 17, 2022 by Robin Kearey 9 Comments

Electromagnetic interference problems can be a real headache to debug. If you need to prove what causes your WiFi to slow down or your digital TV signal to drop, then the ability to measure electromagnetic fields (EMF) can be a big help. Professional equipment is often very expensive, but building an EMF detector yourself is not even that difficult: just take a look at Arduino expert [Mirko Pavleski]’s convenient hand-held electromagnetic field detector.

The basic idea is quite simple: connect an antenna directly to an Arduino’s analog input and visualize the signal that it measures. Because the input of an ADC is high impedance, it is very sensitive to any stray currents that are picked up by the antenna. So sensitive in fact, that a resistor of a few mega-Ohms to ground is required to keep the sensor from triggering on any random kind of noise. [Mirko] made that resistance adjustable with a few knobs and switches so that the detector can be used in both quiet and noisy environments.

Making the whole device work reliably was an interesting exercise in electromagnetic engineering: in the first few iterations, the detector would trigger off its own LEDs and buzzer, trapping itself in a never-ending loop. [Mirko] solved this by encasing the Arduino inside a closed, grounded metal box with only the required wires sticking out. The antenna’s design was largely based on trial-and-error; the current setup with a 7 cm x 3 cm piece of aluminium sheet seemed to work well.

While this is not a calibrated professional-grade instrument, it should come in handy to find sources of interference, or even simply to locate hidden power cables. You can view this as a more advanced version of [Mirko]’s Junk Box EMF Detector; if you have a second Arduino lying around, you can use that one to generate interference instead. Continue reading “Measuring Electromagnetic Fields With Just An Arduino And A Piece Of Wire” →

A purple PCB with an OLED display and various chips

A Neat Little Tool To Reset The Fuses On Your ATtiny

April 16, 2022 by Robin Kearey 8 Comments

If you’re an experienced hacker, you’ve probably run into a problem at some point and thought “let’s make a tool to automate that”. A few hours later you’ve got your tool, but then realize that the amount of work you put into making the tool vastly exceeds what you would have needed to solve the original problem manually. That really doesn’t matter though: developing a fancy tool can be a rewarding experience that teaches you way more about the original problem than you would have learned otherwise. [sjm4306]’s ATtiny High Voltage Fuse Reset-er is a clever device that firmly falls into this category.

The problem it solves is familiar to anyone who’s ever worked with Atmel/Microchip’s ATtiny series of microcontrollers: set one of the configuration fuses incorrectly and you’re no longer able to reprogram your chip. Getting the ATtiny back to its original configuration requires a high-voltage programming step that involves pulling the reset pin to 12 V in what’s otherwise a 5 V system. You could simply grab a spare 12 V supply and hack together a level shifter with a few transistors, but where’s the fun in that?

[sjm4306]’s solution is built on a pretty purple PCB that contains an ATmega328, an OLED display, and sockets to accommodate various versions of the ATtiny series microcontrollers. To generate the required 12 V, one could simply use an off-the-shelf boost converter IC. But instead, he decided it would be interesting to make such a circuit out of discrete components and control it using the ATmega. After all, this chip already contains timers to generate PWM signals and an ADC to measure the converter’s output voltage, so all it took was to write some control logic in the form of a PID controller.

The end result, as you can see in the video embedded below, is a convenient little PCB that runs off a 5 V USB power supply and resets the fuses on your ATtiny at the push of a button. Sometimes, simple tools that do one thing well are all you need; however, if you’re looking for an all-in-one AVR programmer that also supports HV programming, check out this AVR Multi-Tool.

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Tiny Pneumatic Tool Made From A Single(-ish) Bolt

April 16, 2022 by Dan Maloney 17 Comments

We’ve noticed a couple of things about the “Widget from a Single Bolt” genre of metalworking videos. The first thing is that almost all of them need to use a freakishly large bolt, and many of them also rely on other materials to complete the build. And secondly, these builds all pretty much depend on a lathe to transform the bolt into the intended widget.

While this single-bolt pneumatic graving tool build is guilty on that first count, it somehow manages to avoid needing a lathe. Not that [AMbros Custom] wouldn’t have greatly benefited from a lathe to make this somewhat specialized and unusual tool a reality. A graving tool or graver is used during metal engraving, the art of making controlled cuts into flat metal surfaces to render complicated designs. A powered graver like this can make engraving faster and more precise than a traditional manual graver, which is typically powered by light taps with a special hammer.

The lathe-less build [AMbros] undertook was quite ambitious given the number of moving parts and the tight tolerances needed for a pneumatic tool. The real hero here is the hand drill pressed into service as an impromptu lathe; teamed with various tools from files to emery cloth to even a Dremel and an angle grinder, it did a respectable job turning down the various parts. The entire build is shown in the video below, and it’s worth a watch just to see what ingenuity can accomplish when coupled with sheer persistence.

Hats off to [AMbros] for sticking with what was admittedly a problematic build, and here’s hoping a lathe is in his future. With that, he may be able to pull off other impressive “single-bolt” builds, like this combination padlock. Or throw another bolt or two in and pull off this cryptex-like safe.

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Versatile Reflow Oven Controller Uses ESP32-S2

April 14, 2022 by Al Williams 12 Comments

[Maker.Moekoe] wanted a single controller board that was usable with different reflow ovens or hotplates. The result is a versatile board based on the ESP32-S2. You can see a video of the board’s assembly in the video below.

The board sports several inputs and outputs including:

2x MAX6675 thermocouple sensor input
2x Fan output with flyback diodes
2x Solid state relay output
3x Buttons
1x LED
1x Buzzer
1x Servo motor output
0.96 inch OLED display

You could probably find a use for the board for other similar applications, not just ovens.

The video is oddly relaxing, watching parts reflow. It is like watching a 3D printer, no matter how many times we see it, we still find it soothing to watch. You can also see how he integrated the board with a toaster oven.

Overall, the board looks great and the workmanship is also very good. If you’ve never seen anyone set heat-set threaded inserts into a 3D printed piece, be sure to watch around the four minute mark.

We’ve seen plenty of oven projects. You can even use an Easy Bake oven.

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