If The Blade Sees Its Shadow, It’s Another 64th Of Accuracy

September 11, 2022 by Matthew Carlson 43 Comments

If you’ve bought a miter saw in the past few years, you might have noticed the LED “laser” that came with it. The goal was to show where on the piece the saw was going to cut. But over a year or two, you might have found the laser to have drifted or skewed into a crooked line. [Fisher] decided that his after-market laser wasn’t entirely accurate enough and added a shadow line instead. (Video, embedded below the break.)

The blade has a thickness (known as kerf), and with a laser to one side, you can only accurately cut on one side of the line. A shadow line works differently. By shining a line at the top of the blade, you get a mark where the blade will cut precisely. You can also see your marks as the laser doesn’t shine over them. Previously, [Fisher] had tried to use LED strips, but after a comment suggested it, he found a sewing light on a gooseneck. It worked great as a small compact light fitting the blade housing. After some quick modifications, hot glue, and duct tape, the light was installed, and the wires were routed while still allowing the saw its full range of motion.

The result is impressive, with a clear shadow on even darker hardwoods. Just the few test cuts he made seemed entirely accurate. Of course, you can always go deeper down the hole of accuracy and measurement. But overall, [Fisher] has a great little mod that speeds up his workflow more accurately. Continue reading “If The Blade Sees Its Shadow, It’s Another 64th Of Accuracy” →

Ask Hackaday: Stripping Wires With Lasers

September 8, 2022 by Al Williams 22 Comments

Most of us strip the insulation off wires using some form of metal blade or blades. You can get many tools that do that, but you can also get by with skillfully using a pair of cutters, a razor blade or — in a pinch — a steak knife. However, modern assembly lines have another option: laser stripping. Now that many people have reasonable laser cutters, we wonder if anyone is using laser strippers either from the surplus market or of the do-it-yourself variety?

We are always surprised that thermal strippers are so uncommon since they are decidedly low-tech. Two hot blades and a spring make up the heart of them. Sure, they are usually expensive new, but you can usually pick them up used for a song. The technology for lasers doesn’t seem very difficult, although using the blue lasers most people use in cutters may not be optimal for the purpose. This commercial product, for example, uses infrared, but if you have a CO₂ laser, that might be a possibility.

The technique has found use in large-scale production for a while. Of course, if you don’t care about potential mechanical damage, you can get automated stripping equipment with a big motor for a few hundred bucks.

We did find an old video about using a CO₂ laser to strip ribbon cable, but nothing lately. Of course, zapping insulation creates fumes, but so does lasering everything, so we don’t think that’s what’s stopping people from this approach.

Continue reading “Ask Hackaday: Stripping Wires With Lasers” →

Custom Lathe Tool Cuts Complex Oil Grooves

September 8, 2022 by Anne Ogborn 41 Comments

Oil grooves are used to lubricate the inside of a bearing, and can come in many forms — from a single hole that takes a few drops of oil, to helical patterns that distribute it over the entire internal surface. The ideal arrangement is a looping figure eight pattern similar to an oscilloscope Lissajous figure, but cutting these is a nightmare. That is, unless you’ve got the proper tool.

We figure [Machine Mechanic] must need to cut a lot of them, as they spent quite a bit of time perfecting this custom lathe attachment to automate the process. Through an assortment of clever linkages and a rod-turned-crank that was welded together in-situ, the device converts the rotational motion of the lathe into a reciprocating action that moves the cutting tool in and out of the bearing. Incidentally the business end of this gadget started life out as a bolt, before it was turned down and had a piece of tool steel brazed onto the end.

With a little adjustment, it seems like this device could also be used to carve decorative patterns on the outside of the workpiece. But even if this is the only trick it can pull off, we’re still impressed. This is a clever hack for a very specialized machine shop operation that most would assume you’d need a four-axis CNC to pull off.

Lathes seem at first like rather single purpose machines, we’re always pleased to discover strange and wonderful things being done with them, like this seemingly impossible-to-turn piece, and this combo wire EDM and lathe.

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DIY Fume Extractor With ATtiny13 Speed Control

September 4, 2022 by Tom Nardi 15 Comments

Let’s be honest, commercially-available soldering fume extractors are cheap enough that you probably don’t need to build one yourself. But it still makes for a good starter project, especially if you go out of your way to really flex your maker muscles like [Arnov Sharma] did with this tidy build.

All the hallmarks of modern hardware making are on display here — you’ve got the 3D printed enclosure, a motor salvaged from a cheap toy quadcopter, and a custom PCB which uses the ATtiny13 and an AO4406 MOSFET to implement a PWM speed control.

The first press of the button starts the motor off at max speed, but keep pushing it, and the motor’s speed will ramp down until it turns off entirely. There’s even a TP4056 charge controller to top off the internal 18650 cell when the fume extractor is connected to a USB power source.

Is it over-engineered? Perhaps. But projects like these are a great opportunity to practice your skills, whether it’s PCB design or creating bespoke 3D printed enclosures. In the era of cheap 32-bit microcontrollers, it’s also refreshing to see hackers still dragging the ATtiny from time to time.

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Plotter Churns Out Labels With Roll Of Tape

September 3, 2022 by Danie Conradie 24 Comments

Like it or not, organizing your workspace from time to time is a necessary chore. Labels can go a long way towards taming the most unruly of benches, but writing them out by hand isn’t exactly ideal. Looking for something a bit neater, [sandy] built a simple pen plotter to write labels on a roll of tape.

The plotter uses the usual 3D printer components like steppers, drivers, belts, and rails. The tape holder is printed with flexible arms for a tight grip, and a servo is used to raise and lower the pen while writing.

The custom control board includes an Arduino Nano clone and a pair of stepper drivers, and an optional Bluetooth module and can be configured for a variety of machine control applications. A pair of Android apps are used to generate and send the G-code from a phone to the GRBL firmware loaded on the Arduino.

This seems to fall in the category of “entry-level” custom automation tools which help to save some time and effort on repetitive tasks without blowing the budget. We would include the various component tape cutters we’ve seen in this category, as well as smart build platform for manual PCB assembly

Cutting The Grass With Frickin’ Lasers

September 2, 2022 by Dave Rowntree 29 Comments

We techie types are quite often much more comfortable in front of a keyboard knocking out code, than out in the yard splitting logs for winter, and even the little jobs like cutting the grass are sometimes just too much like hard manual labour for our liking. The obvious solution is a robot mower, but they’re kinda boring, with their low-tech spinning metal blades. What we need is a big frickin’ laser. YouTuber [rctestflight] has been experimenting with using a 40W blue diode laser module to cut the weeds, (Video, embedded below) and it sort of works, albeit in a rather dangerous fashion.

The first test used a fixed assembly, mounting the laser to a camera lens, upon a rotating gear driven by a small stepper motor. An Arduino controls the beam scanning, very slowly, burning the grass in its sights. But with a range limited to around eight feet best case, sitting in one spot just isn’t going to cut it. (sorry) The obvious next step was to mount one of the tested laser modules onto a moveable platform. After tweaking one of his earlier projects — a tracked rover — with a new gearbox design, it could now drive slow enough to be useful for this slow task. The laser was mounted to a simple linear rail slider, with an attempt at a vacuum pickup system to suck up the clippings, removing them from the beam path, and stopping them impeding the cutting efficiency of the laser.

Obviously this vacuum idea didn’t work, and since the contraption takes the best part of a week to cut just one small area, we reckon it would likely be growing faster than that! Still, it must have been fun to build it anyway. It just goes to show that despite the march of technological progress, maybe the boring old spinning blades of old are still the best way to get the job done.

Lawnmowing is clearly one of those jobs we love to hate, and do so with hacks. Here’s a way to prevent your mower sucking up foreign bodies and hurling them at you at ballistic speeds, and for those who really want to be hands off, add RTK-GPS to a robot mower, and just leave it to do the dirty work.

Continue reading “Cutting The Grass With Frickin’ Lasers” →

Finished pipe crimper made from recycled parts

Making A Pipe Crimper From Scrap

August 30, 2022 by Dave Rowntree 19 Comments

We love upcycling around these parts — taking what would be a pile of rusty scrap and turning it into something useful — and this project from YouTuber [Hands on Table] is no different. Starting with a pair of solid looking sprockets, one big, one small, and some matching chain, a few lumps of roughly hewn steel plate were machined to form some additional parts. A concentric (rear mounted) plate was temporarily welded to the sprocket so matching radial slots could be milled, before it was removed. Next, the sprocket was machined on the inside to add a smooth edge for the crimping fingers (is that the correct term? We’re going with it!) to engage with.

These fingers started life as an off the shelf 3/8″ HSS tool bit, ground down by hand, to produce the desired crimping profile. A small piece of steel was welded on to each, to allow a small spring to act on the finger, enabling it to retract at the end of the crimping action. We did spot the steel plate being held in place with a small magnet, prior to welding. The heat from that would likely kill off the magnetic field in a short space of time, but they’re so cheap as to be disposable items anyway.

A small ring rides on top of the assembly, bolted to the fixed rear plate. The prevents the crimping fingers from falling out . The fingers are constrained by the slots in the rear plate, so the result is that they can only move radially. As the big sprocket is rotated, they get progressively pushed towards the center, giving that nice, even crimping action. Extra mechanical advantage is provided by driving the small sprocket with a wrench. Super simple stuff, and by the looks of the device in action, pretty effective at crimping the hose fittings it was intended for.

Taking one thing and turning it into something else may well be the very essence of hacking. We’ve seen many hacky upcycling efforts, such as this bench disk sander built from a dryer machine motor. Of course, upcycling is not limited to machines, tools and electronic doodads. Here a trapper hat made out of an old skirt. And why not?

Continue reading “Making A Pipe Crimper From Scrap” →