Master craftsperson turns a huge bolt into a pneumatic engraving tool.

Impressive Hack Turns Bolt Into Pneumatic Engraver

December 2, 2021 by Kristina Panos 24 Comments

Did you ever see one of those videos that causes you to look at an everyday object in a new light? This is one of those videos (embedded below). And fortunately for us, there’s a write-up to go along with it in case you don’t always understand what’s going on.

In this case, what’s going on is that [AMbros Custom] is masterfully turning a stainless steel M20 bolt into a pneumatic engraving tool. Yeah, you read that correctly. But the most amazing thing about this hack is the minimum of tools used to do it. For one thing, there’s not a lathe in sight — [AMbros Custom] just chucked it into the drill or added a few nuts and clamped it in a vise.

So, how does it work? [AMbros Custom] hooks it up to a compressor, which causes the piston inside to go up and down, agitating the engraving bit. If you don’t want to watch the video, there are a ton of build pictures in the write-up.

What else can you do with a bolt? If you have the tools, you can do plenty. You could even turn one into a secret cash stash for buying more large bolts.

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Two-Stage Dust Collector Recycles Blasting Media

November 30, 2021 by Tom Nardi 4 Comments

A critical element of a good blasting cabinet setup is a vacuum system that can suck out the dust, blasting media, and bits of removed material faster than it collects inside the chamber. A cyclone separator can get the job done, but since it dumps all the waste from the cabinet into one bucket, it can make reusing the blasting material a dirty job. But as [Daniel Bauen] explains in the latest Engineerable video, his two-stage dust collector is able to keep the cabinet clear while separating the used blasting material into its own container.

The cheap dust separator only works on large particles.

Basically, the idea here is to to use two different cyclone separators: one that’s very effective, and a cheap model that’s only able to remove large particulates. By running the air from the cabinet through the cheap separator first, the used blasting media is captured in a dedicated bucket. From there, the air runs through the high-efficiency separator to extract the finer dust. Finally, the shop vacuum [Daniel] is using has its own washable HEPA filter to catch anything that makes it through the two extractors; though he notes that it only rarely needs to be cleaned out.

Normally this system is attached directly to the blasting cabinet, and it does a good job of capturing the bulk of the used blasting media in real-time. But to make sure the media is really cleaned up being using it again, [Daniel] will actually run the contents of the first bucket through the system a few more times to separate out any of the more stubborn dust that might be mixed in.

Of course not everyone has the space, or even the need, for such an elaborate blasting setup. If you’re just trying to quickly clean up some parts on the cheap, you can make a basic blaster for around $6. Good luck capturing the media though.

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Solder Paste Dispenser Without Giant Compressor

November 26, 2021 by Bryan Cockfield 25 Comments

We have certainly all had our moments with solder paste. Some of us hate it; it’s sticky and gooey, and it gets everywhere. That is, unless you have a solder paste dispenser. The trouble with these is that they typically require the use of an air compressor, which can be cumbersome to haul around in certain situations. If you need a solder paste dispenser that fits conveniently where air compressors won’t, take a look at this small one from [Nuri Engineer] called the solderocket.

This design foregoes the traditional compressor in favor of pressurized carbon dioxide canisters. These are common enough and used for things like rapidly inflating bicycle tires, but for this more delicate procedure the pressurized gas needs to be handled more daintily. A rotary knob is attached to the canister to regulate pressure, and a second knob attached to a microcontroller adjusts the amount of time the air pressure is applied to the solder paste. With this small compact setup, any type of paste can be delivered to a PCB without needing to use messy stencils or needing larger hardware like a compressor.

This could be just the tool that you need if you regularly work with surface-mount components. Of course there are other methods of dispensing solder paste that don’t require any compressed gas of any kind, but as long as something is around that gets the job done, we can’t really argue with either method.

Science Vs Internet Trolls: Testing Another Kind Of File System

November 24, 2021 by Dan Maloney 39 Comments

No matter what you do or say on the Internet, you’re always doing it wrong. Keyboard commandos are ready to pounce and tell you how it’s “ackchyually” supposed to be done. And so it was of little surprise when [Jason] of Fireball Tools was taken to task by the armchair millwright for his supposedly deficient method of filing metal.

But [Jason] chose to fight back not with words but deeds, building a system to test alternative methods of filing. His filing style is to leave the file in contact with the stock on both the front- and back-strokes, which enraged those who claim that a file must never be dragged back over the workpiece, lest the teeth become dull. The first video below shows the build of the test rig, which leveraged his enormous Cinncinatti shaper as the prime mover, as well as a pneumatic jig to hold the workpiece and imitate both styles of filing. Part two below shows the test rig in action, and [Jason] really outdoes himself with his experimental approach. He tested three different grades of Pferd files — nothing but the best, no expense spared — and did duplicates of each run using both the Internet-approved style and his lazier style.

The result? We won’t spoil that for you, but suffice it to say that the hive mind isn’t always right. And what’s more, [Jason]’s careful myth-busting yielded a few interesting and unexpected results. His channel is full of great shop tips and interesting builds, so check him out if you want to see how metalworking is done.

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Oscilloscope Probes Itself To Add Video

November 24, 2021 by Robin Kearey 12 Comments

Modern oscilloscopes are often loaded with features, but every now and then you run into a feature that seems easy to implement yet isn’t available. [kgsws] wanted to use his Rigol DS1074 to show live measurements in his YouTube videos, but found out that this scope doesn’t support video output. Not to be deterred, [kgsws] decided to add this feature himself. In the video embedded below, he describes in detail the process of adding a USB Video Capture (UVC) interface to his oscilloscope.

The basic idea was to find the signals going into the scope’s display and read them out using a Cypress EZ-USB board. This is a development board that can be used to design USB devices, and supports the UVC mode. However, with no documentation of any of the Rigol’s internal circuitry [kgsws] had to probe the display connector to find out which pin carried which signal. And since he had no other scope available than this Rigol, he hooked up the various bits of the disassembled instrument so that it could (awkwardly) probe its own internal signals.

After mapping out its own display signals, it was time to hook them up to the EZ-USB board. [kgsws] achieved this by soldering about two dozen tiny wires to SMD pads on the motherboard. The EZ-USB board itself was placed in the back of the scope’s case, but had to be stripped of unneeded components in order to save space and power. A very clever trick was the addition of a reed switch, which allowed [kgsws] to set the EZ-USB board to programming mode without having to open the scope’s case, by simply holding a magnet near the switch.

After soldering a USB connector into a spare slot in the RF shield the project was complete. The Rigol can now be connected to a PC and will simply appear as a video capture device, ready to be streamed or captured for [kgsws]’s future project videos. We’ve seen other hacks on the Rigol DS1000Z series to capture a series of screenshots or to enable additional bandwidth and features, but adding a live video output was not one of the options so far. Continue reading “Oscilloscope Probes Itself To Add Video” →

Shop-Built Rig Measures Strength Of Wood Accurately

November 22, 2021 by Dan Maloney 7 Comments

Wood is an incredibly versatile material, but like everything else, it has its limits. Build a chair from weak wood and the worst that can happen is probably not that bad. But if you build machine tools from wood, the stakes for using the wrong wood can be a bit higher.

That’s the thinking behind the wood strength testing setup [Matthias Wandel] came up with. Previously, he had a somewhat jury-rigged test setup with a hydraulic bottle jack to apply force to the test piece and a bathroom scale to make measurements. That setup was suboptimal, so version two used a jackscrew to apply the force, but the bathroom scale still left the measurements open to interpretation. Version three, the topic of the video below, went with strain gauges and an A/D converter connected to a Raspberry Pi to automate data collection. The jackscrew was also integrated into the test setup with a stepper motor and, of course, [Matthias]’ famous wooden gears.

While the test rig is pretty simple in design, there’s a lot of subtlety to the calibration to make sure that it’s measuring the test material itself and not just compliance within the mechanism. It’s just another in a long line of data-gathering exercises that [Matthias] seems to groove on, like his recent woodshop electrical explorations.

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Improving A Mini-Lathe With A Few Clever Hacks

November 13, 2021 by Dan Maloney 21 Comments

Like many budget machinists, the delightfully optimistically named [We Can Do That Better] had trouble with some of the finer controls on his import mini-lathe. But rather than suffer through it, he chose to rectify the machine’s shortcomings and in the process, teach everyone a bunch of great tips.

[We Can Do That Better]’s lathe retrofit focused on the carriage handwheel, which appears to lack proper bearings and wobbles around in a most imprecise manner. On top of that, the gearing of the drive made for an unsatisfying 19 mm of carriage travel per revolution of the handwheel. A single gear change made that an even 20 mm per rev, which when coupled with a calibrated and indexed handwheel ring greatly simplifies carriage travel measurements.

While the end result of the build is pretty great in its own right, for our money the best part of the video is its rich collection of machinist’s tips. The use of a wooden dowel and a printed paper template to stand in for a proper dividing head was brilliant, as was using the tailstock of the lathe to drive an engraving tool to cut the index lines. We’ve seen the use of a Dremel tool mounted to the toolpost to stand in for a milling machine before, but it’s always nice to see that trick used. And the mechanism for locking the dial to the handwheel was really clever, too.

Considering a mini-lathe? As encouraging as [We Can Do That Better]’s experience may be, it might be wise to take a deep dive into the pros and cons of such a machine.

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