How To Cast Silicone Bike Bits

April 26, 2024 by Jenny List 19 Comments

It’s a sad fact of owning older machinery, that no matter how much care is lavished upon your pride and joy, the inexorable march of time takes its toll upon some of the parts. [Jason Scatena] knows this only too well, he’s got a 1976 Honda CJ360 twin, and the rubber bushes that secure its side panels are perished. New ones are hard to come by at a sensible price, so he set about casting his own in silicone.

Naturally this story is of particular interest to owners of old motorcycles, but the techniques should be worth a read to anyone, as we see how he refined his 3D printed mold design and then how he used mica powder to give the clear silicone its black colour. The final buses certainly look the part especially when fitted to the bike frame, and we hope they’ll keep those Honda side panels in place for decades to come. Where this is being written there’s a CB400F in storage, for which we’ll have to remember this project when it’s time to reactivate it.

If fettling old bikes is your thing then we hope you’re in good company here, however we’re unsure that many of you will have restored the parts bin for an entire marque.

Keeping Alive The Future Of Cars, 1980s Style

April 21, 2024 by Jenny List 18 Comments

Here at Hackaday we’re a varied bunch of writers, some of whom have careers away from this organ, and others whose work also appears on the pages of other publications in different fields. One such is our colleague [Lewin Day], and he’s written a cracking piece for The Autopian about the effort to keep an obscure piece of American automotive electronic history alive. We think of big-screen control panels in cars as a new phenomenon, but General Motors was fitting tiny Sony Trinitron CRTs to some models back in the late 1980s. If you own one of these cars the chances are the CRT is inoperable if you’ve not encountered [Jon Morlan] and his work repairing and restoring them.

Lewin’s piece goes into enough technical detail that we won’t simply rehash it here, but it’s interesting to contrast the approach of painstaking repair with that of replacement or emulation. It would be a relatively straightforward project to replace the CRT with a modern LCD displaying the same video, and even to use a modern single board computer to emulate much of a dead system. But we understand completely that to many motor enthusiasts that’s not the point, indeed it’s the very fact it has a frickin’ CRT in the dash that makes the car.We’ll probably never drive a 1989 Oldsmobile Toronado. But we sure want to if it’s got that particular version of the future fitted.

Lewin’s automotive writing is worth watching out for. He once brought us to a motorcycle chariot.

DIY Quad-Motor Go-Kart Is A Thrilling Ride

April 18, 2024 by Donald Papp 28 Comments

[Peter Holderith] set out some time ago to build an electric go-kart. That by itself is not terribly unusual, but where his project diverts from the usual is in the fact that each of the four wheels has an integrated hub motor.

It might not look it, but each wheel has an integrated hub motor.

This kart project is a bit of a work in progress, with [Peter] previously building (then scrapping) a failed attempt at a cheap suspension system. But it’s completely operational with all four wheels able to deliver a monstrous amount of power despite being limited by the power supply (a battery pack salvaged from an Audi Q5 Hybrid).

The kart might not look it, but it weighs 177 pounds (80 kg) with the battery and motors accounting for nearly half of that. What is is like to drive? “Nothing short of thrilling,” says [Peter]. It’s got no suspension and is pretty bare bones, not to mention limited in power by the battery, but [Peter] finds it a satisfying drive that nevertheless delivers car-like cues in the driving experience. The build isn’t done, and [Peter] plans to see if more power is available by switching battery chemistries rather than add more battery weight.

Building and driving electric vehicles can be remarkably satisfying, and it’s an area in which hobbyists can meaningfully innovate. Self-balancing one-wheeled vehicles for example look like a ton of fun. Heck, researchers have discovered that even rats seem to enjoy driving just for the fun of it.

Kid’s Ride Gets Boosted Battery, ESP32 Control

April 6, 2024 by Tom Nardi 15 Comments

That irresistible urge to rescue an interesting piece of hardware from the trash is something that pretty much every Hackaday reader will have felt at one time or another. Sometimes it’s something that you could put to work immediately, like an old computer or some scrap piece of material that’s just the right size. But other times, you find something on the side of the road that ends up being the impetus for a whole new project.

For [David Bertet], finding a beat up kid’s Jeep Wrangler on the curb was the first step towards a journey that ends with PowerJeep: an open source project that we wager could end up saving similar vehicles from the landfill. The basic idea is simple enough — strip out the vehicle’s original 12 volt power supply and replace it with 18 V provided by easily swappable tool batteries. But as is often the case, it’s the details and the documentation that sets this project apart.

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A Drone Motor Does E-Bikes

April 5, 2024 by Jenny List 37 Comments

On paper, the motors from both an electric bicycle and a drone can both take about 500 watts or so of power. Of course, their different applications make them anything but equivalent, as the bike motor is designed for high torque at low speed while the drone motor has very little torque but plenty of speed. Can the drone motor do the bike motor’s job? [Pro Know] makes it happen, with a set of speed reducing and torque increasing belts.

The build takes a pretty ordinary bicycle, and replaces the rear brake disk with a large pulley for a toothed belt, which drives a smaller pulley, and through a shaft another set of pulleys to the drone motor. The bracket to hold all this and the very large pulley on the wheel are all 3D printed in PLA-carbon fiber mix.

When it’s assembled, it runs the bike from a small lithium ion pack. That’s not unexpected, but if we’re honest we’d have our doubts as to whether this would survive the open road. It’s evidently a novelty for a YouTube video, and we’d be interested to see how hot the little motor became. However what’s perhaps more interesting is the choice of filament.

Could carbon fibre PLA be strong enough to print a toothed belt pulley? We’d be interested to know more. We saw the same filament combo being tested recently, after all.

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TOMOS Moped Becomes Electric Beast

April 4, 2024 by Jenny List 12 Comments

The TOMOS 50cc moped, a small motorcycle produced in Yugoslavia and the Netherlands, has for decades been a common sight on European roads and provided the first taste of transport independence for countless youngsters. Unfortunately the company went bankrupt a few years ago, but there are still plenty of them about, and it’s one of these that [Doctor D.S.] gives an electric conversion in the video below the break.

The electronics are a standard 5 kW off-the-shelf Chinese kit, but in this they aren’t the star of the show so much as the work on the bike. As with any old moped it’s a bit ropey, and he strips it down and reconditions every part of it alongside his work fabricating brackets, a battery box, and a seat. It’s a long video, but it’s one of those workshop sequences that you can become engrossed in.

The result appears to be a very practical, powerful (for a moped) and rideable bike, and it’s one we’d have for buzzing around town any day. We’d like to take a look at that battery box and seat combo on the interests of safety, but otherwise it’s pretty spot-on. Sit back and enjoy a bit of quality workshop video!

If you’re hungry for more, this is by no means the first road bike electric conversion we’ve brought you.

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Where Graph Theory Meets The Road: The Algorithms Behind Route Planning

April 4, 2024 by Maya Posch 32 Comments

Back in the hazy olden days of the pre-2000s, navigating between two locations generally required someone to whip out a paper map and painstakingly figure out the most optimal route between those depending on the chosen methods of transport. For today’s generations no such contrivances are required, with technology having obliterated even the a need to splurge good money on a GPS navigation device and annual map updates.

These days, you get out a computing device, open Google Maps or equivalent, ask it how you should travel somewhere, and most of the time the provided route will be the correct one, including the fine details such as train platform and departure times. Yet how does all of this seemingly magical route planning technology work? It’s often assumed that Dijkstra’s algorithm, or the A* graph traversal algorithm is used, but the reality is that although these pure graph theory algorithms are decidedly influential, they cannot be applied verbatim to the reality of graph traversal between destinations in the physical world.

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