Wooden Flatbed Truck Conversion

July 23, 2013 by Mike Szczys 55 Comments

wooden-flatbed-truck-conversion

This pickup truck to flatbed conversion is very impressive. [Caswell_Etheredge] says he was channeling his inner redneck. That must mean rednecks in his area are craftsmen of the highest caliber.

He wanted a bit more flexibility on the size and shape of the cargo he was able to haul. Just six lag bolts held the original stamped steel bed on the truck. A bit of work with a pipe and a breaker bar did the trick. A mess of packed on mud and grime was there to greet him. After chipping, vacuuming, and power washing the underbody he gave it a fresh paint job using an undercoating product.

From there the wood flatbed build starts, and he’s not messing around with scrap wood. What you can see of the bed is fashioned from cedar and ipe. The underpinnings which fasten to the frame with those same six lag bolts are pressure treated 2×4 boards. The 4×6 bumper includes the license plate and lights for it. Brake and turn signals are built into the bed along with cleats for easy fastening of a tarp or to secure the cargo.

[via Reddit]

DIY Airbag, Explosions Included

July 14, 2013 by Brian Benchoff 16 Comments

AnAirbagSavedMyLife

Your car’s airbag is one of the major engineering accomplishments of the auto industry. In an accident, a whole host of processes must take place in sequence to keep your face from slamming into the steering wheel, and everything must happen in just a fraction of a second. [Steve] over at Make thought it would be a cool idea to discover what actually goes in to saving a life with an airbag and decided to build his own.

The electronics of the build consisted of an accelerometer and an Arduino. A lot of research, development, and experimentation has gone into the algorithms that trigger airbags, but [Steve] decided to keep things simple: when a sudden acceleration is detected, set off a small charge of black powder.

The airbag itself is ripstop nylon reinforced with canvas, contained in a small wooded box fitted with hinged doors. All these components are put on wheeled aluminum test rig, manned with a honeydew melon crash test dummy, and pulled into a short wall at a few miles per hour.

Despite [Steve] not putting hundreds of thousands of man hours into the development of his airbag – unlike the ones you’ll find in your steering column – his device actually worked pretty well. While not a complete success, he did manage to come up with something that both looks and acts like the familiar device that has saved countless lives.

Human Powered Flight Extravaganza

July 13, 2013 by Brian Benchoff 18 Comments

humanpoweredflight

In case you haven’t heard, the Sikorsky Prize, an aeronautical challenge to build a human-powered helicopter that can hover at three meters for a full sixty seconds, has been claimed. This incredibly difficult engineering feat was accomplished by AeroVelo, along with a lot of help from the University of Toronto and a host of companies involved in the design and manufacture of rotorcraft. This prize has stood unclaimed for thirty years, and it’s not from lack of trying; in the 80s and 90s, universities in Japan tried their hand at the challenge, and recently a team from the University of Maryland had a go at it.

But as far as human-powered flight goes, a helicopter is just about the least efficient way to get off the ground. Helicopters need power to provide their own lift and thrust, whereas airplanes only need to generate some forward momentum.

From the bicycle-powered crossing of the English channel in 1979, human-powered flight has come a long way, so far that next the Royal Aeronautical Society will be hosting the Icarus Cup 2013. It’s a competition where teams of human-powered aircraft enthusiasts will compete in challenges measuring distance, speed, endurance, and landing accuracy.

No, it’s not an ornithopter from Da Vinci’s notebook, but human pectoral muscles aren’t powerful enough for that anyway.

Thanks [DainBramage1991] for sending this one in.

Teardrop Camper Combines Simplicity, Style, And Function

July 10, 2013 by Mike Szczys 1 Comment

They needed a place to stay on road trips and at music festivals. This teardrop camper certainly fits the bill. And it’s got a look that will make you proud to unfold yourself into the parking lot every morning.

Starting from a flat frame the camper skeleton was built up using plywood sides and cross pieces to help support the sweeping roof. It was then covered with 1/4″ Birch plywood which has enough flexibility to follow the contour. Inside you won’t find much in the way of frills, but the entire floor is a 4″ thick foam mattress which is a lot better that camping out. There’s a dome on top which can opens for ventilation and a hatch on the rear to carry some extras along on your adventure.

[via Reddit]

Manual Transmission For Gamers

July 7, 2013 by Mike Szczys 53 Comments

manual-transmission-for-gamers

If that stick shift just doesn’t feel right in your hand it’s time for a change. This hack puts a gaming joystick in the center console of your hoopty as a gear shifter.

[Ilias] used a joystick from about 1991 to replace the stock shifter. It jogs our memory when he mentions that this thing saw a lot of use playing X-wing vs. Tie Fighter. Boy did we burn up a ton of time playing that one too! He actually broke the stock part getting it off (find a shop manual for your car if you’re afraid of this). But once the grip was removed he was relieved to find the joystick fit perfectly. The two molded plastic halves of the joystick screw together. To join them with the shifting level he used epoxy putty.

The momentary push switch for that thumb button is still in there. But it doesn’t look like he hooked it up to anything. If we were to give this one a try we’d have to find some use for it. Got any suggestions? Let us know in the comments.

3D Printed Bike Shifter

July 7, 2013 by Brian Benchoff 26 Comments

Shifter

[Rich] is embarking on a fairly long bike trip in a few weeks – Seattle to Portland – and thought including some 3D printed gear on his ride would be a fun endeavor. His first idea was a printed belt drive, but the more he looked at that idea the less realistic it seemed. He finally hit upon the idea of creating a 3D printed bike shifter, and after an afternoon of engineering and printing, the shifter ended up working very well.

[Rich]’s shifter is actually a friction shifter. Instead of ‘clicking’ into position, this type moves the derailleur gradually. It’s much more tolerant of slight misalignment, and most touring bikes – the type that would embark on long journeys along the coast of the Pacific northwest – have these types of shifters.

Total printing time was about one and a half hours, and was attached to [Rich]’s bike with off-the-shelf hardware. He’s already put about 150 miles on his custom designed shifter with no signs of failure.

Building A 70-foot Sailboat In Oklahoma

July 5, 2013 by Brian Benchoff 2 Comments

Call it a retirement plan, a hobby, or a beautiful expression of a mental imbalance, but [Doug and Kay Jackson] of Tulsa, OK are building a seventy-four foot steel sailboat in their backyard.

For the last few years, the couple has been working on the SV Seeker, a motor sail junk, since late 2011. They have a wonderful build log, but they’ve also gone the extra mile and documented the entire build process on video. Their YouTube channel is one of the best subscriptions you can have on the site, constantly updated with new portions of the build.

Yes, building an oceangoing ship in a landlocked state may seem like an ill-informed idea, but Tulsa, OK is the home of the port of Catoosa, about 400 miles and 20 locks from the Mississippi river, then another 600 miles to the Gulf of Mexico and the open ocean.

Below you can find some of the highlights of [Doug] and [Kay] fabricating the prop for their ship. First, a pattern was created with a CNC machine, then a mold was made to cast each blade in brass. It’s an impressive bit of work putting all these tools together, and you really get a sense of the challenge of building something this big.

Continue reading “Building A 70-foot Sailboat In Oklahoma” →