Hacking Skis, Rules, And Friendships

March 13, 2023 by Bryan Cockfield 15 Comments

The American Birkebeiner is the second largest cross-country skiing race in the world and is quite a big deal within that sport. At 55 kilometers it’s not a short event, either, requiring a significant amount of training to even complete, let alone perform well enough to be competitive. Around a decade ago, friends [Joe] and [Chris] ran afoul of the rules when [Joe] accidentally won the race wearing [Chris]’s assigned entry number, a technicality that resulted in both being banned from the race for two years. Now they’re back, having learned their lesson, and are strictly adhering to those rules this time using these tandem cross-country skis.

The idea for this build was to make sure they could both compete in the race and win because they’d compete in a category no one enters, mostly because it effectively didn’t exist before these two invented it. This required a custom set of skis, but since ski manufacturers don’t typically make skis for two people, they had to get creative. The duo picked up the longest pair of skis they could find at their local ski shop, moving the bindings forward on the skis to make room for the second set of bindings that were added to the back.

This presented a few unique challenges, the first of which is that cross-country skis typically use a special material on the bottom of the skis which grabs the snow to make uphill travel possible, and with the wider distribution of weight this material wasn’t functioning at peak efficiency. The other problem was the stress on the bindings caused by two riders, especially during a crash. This eventually resulted in a broken binding while [Joe] and [Chris] were training. They then upgraded to a more modern pair of skis rated for a single 269-pound rider, had the bindings fitted for two riders, and added a special grip tape over the larger area on the bottom of the ski.

After four months of training and getting in sync, the two were ready for the race. The results are covered in a second video linked below, and while neither of them won the overall race this time, they did finish the event with in-tact skis, first in the new “tandem” class, and completely within the bounds of the strict rules of the race as well. Although winter is winding down in the northern hemisphere, for any of our southern friends looking for some other things to do with an old set of skis for the upcoming winter season, take a look at this sled which adapts some alpine skis to achieve some extremely high speeds.

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27 Litres And 12 Cylinders, With A Practical Station Wagon Body

March 10, 2023 by Jenny List 39 Comments

If you were to name one of the most famous individual road cars in the world, what would it be? If you’re British and of a Certain Age, then it’s possible your nomination is for sale, because “The Beast”, the one-off creation of [John Dodd] using a 27-litre Rolls-Royce Merlin aero engine, is up for auction. The Late Brake Show’s [Jonny Smith] has given it a drive, and we’ve pasted the resulting video below the break.

A second-hand motor isn’t usual Hackaday fare, but it’s the manner of this car’s building which we think will draw you in. [John] originally acquired somebody’s failed project featuring not a Merlin but its de-tuned derivative intended for tanks. He solved the problem of finding a transmission able to handle the immense power, and built it up with a pretty 1970s coupe body. After a fire a few years later he commissioned a new body from a dragster manufacturer, which is the wildly period estate car you’ll see in the video. It famously originally had a Rolls-Royce Cars grille, for which he ended up in court in the 1980s as the carmaker sought successfully to have it removed.

The tale of this car is one of epic scale hackery, as there is quite simply nothing else like it. It was once the world’s most powerful road car, and remains capable of well over 200 miles per hour. Sadly we couldn’t afford to buy it even if we could fit its immense length in our parking space.

Hungry for more epic British car hackery? Have we got the roadster for you!

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A gray 3d-printed box with RV-bridge embossed on it, and a connector-terminated bundle of wires coming out of it.

RV-Bridge Takes HomeKit To The Open Road

March 9, 2023 by Arya Voronova 19 Comments

In the world of proprietary protocol darkness, it’s comforting to see that the RV realm (Recreational Vehicle, also known as a motorhome) has mostly settled on RV-C, an open protocol that lets various devices and systems inside an RV talk to each other over CAN. The undeniable openness of RV-C is surprising, but we haven’t seen many hobbyists tinker with it — yet.

Now, [Randy Ubillos] sets an example — his gift to us is an ESP32 firmware called RV-Bridge and it lets you control your RV’s RV-C network from HomeKit. After all, your motorhome could benefit from home automation, too!

The RV-C network in [Randy]’s family RV already had a factory-provided front-end and an iOS app, but naturally, it had a limited set of features. Having looked around online he found that both RV-C and HomeKit had open libraries for them, and set out to join these worlds together.

Now he’s released the first revision of RV-Bridge, fully-featured enough for comfortable day-to-day use, and with a setup guide for those who want to try it out! When it comes to hardware, you’ll want an ESP32 board with CAN support — [Randy] has found a perfect board for sale, and made it even more fitting by designing a 3D printed case for RV use; as usual, files are on GitHub!

Making your stock RV more comfy through hacker methods is exactly what we expect to grace our tips line! The kinds of RV projects we’ve seen so far, are also outstandingly cool, yet of different kind – things like building your own RVs out of something not meant to be an RV, whether it’s an abandoned airliner, a school bus, or a jet engine! Oh, and if your hackerspace owns a RV, you can always convert it to something else, be it a mobile hackerspace or a spaceship simulator.

A man riding a motorized wooden sled up a snowy hill

Never Walk Uphill Again With This Motorized Sled

March 2, 2023 by Robin Kearey 11 Comments

If you grew up in a snowy climate, chances are you’ve ridden a sled or toboggan when you were young. The downhill part of sledding is great fun, but dragging the thing back up gets boring quickly. [Luis Marx] had been dreaming of sledding uphill since he was a child, and decided to make his dream come true by building himself a motorized sled (video, in German, embedded below).

The sled is powered by two DC electric motors driving a continuous track, like a rudimentary snowmobile. The motors were originally designed for electric bikes, and can develop 30 newton-meters of torque each. [Luis] designed and 3D-printed a custom set of drive wheels to link the track to the bike motors. Two motor controllers enable basic speed control, while a beefy battery carries enough juice for multiple trips up and down a slope.

The motorized track is mounted on a clever frame that can swing up or down and is held in place by two spring-loaded pins. This way, you can simply lift the system off the snow when you’re ready to slide downhil, and swing it down again when you want the sled to do the pulling.

With winter nearing its end, the snow near [Luis]’s home in southern Germany was too soft to get much traction, but subsequent tests in a ski resort up in the Alps showed the system working perfectly. It even had enough traction to pull a second sled behind it. Perhaps some proper suspension could make it go faster on the downhill run, too.

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A line art schematic of a bicycle CVT drive. Two large green circles at the bottom have the text "1. Increases speed" where the crank arm would enter the system. A series of cam arms highlighted in red say "2. Converts from rotary to reciprocating motion." Finally, a blue highlighted bearing says "3. Converts from reciprocating back to rotary motion."

A Look Inside Bicycle Gearboxes

March 2, 2023 by Navarre Bartz 23 Comments

While bicycle gearboxes date back to at least the 1920s, they’re relatively unseen in bike racing. One exception is Honda’s race-winning mid-drive gearboxes, and [Alee Denham] gives us a look at what makes these unique drives tick.

Honda has developed three generations of bicycle gearbox as part of their company’s R&D efforts, but none have ever been released as a commercial product. Designed as a way for their engineers to stretch their mental muscles, the gearboxes were only used in bike races and seen at a few trade shows. In 2004, the third gen “derailleur in a box” led to the first gearbox victory in the Downhill World Cup Circuit.

The third gen gearbox differs significantly from the CVT drivetrains in the first and second generation gearboxes, but it is unclear why Honda abandoned the CVT. [Denham] has a nice animation detailing the inner workings of these CVTs based on information from the original patents for these rarely seen gearboxes.

Derailleurs remain the primary drivetrain in racing due to their lighter weight and higher overall efficiency. While still expensive, the decreased maintenance of gearbox drivetrains make a lot of sense for more mundane cycling tasks like commuting or hauling cargo, but only time will tell if the derailleur can be supplanted on the track and trail.

For more on bicycle drivetrains, check out this chainless digital drivetrain or the pros and cons of e-bike conversions.

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A grey car sits in the background out of focus, its front facing the camera. It sits over an asphalt roadway with a metal rail extending from the foreground to behind the car in the distance. The rail has a two parallel slots and screws surrounding the slots running down the rail.

What Happened To Sweden’s Slot Car EV Road?

March 1, 2023 by Navarre Bartz 60 Comments

Many EVs can charge 80% of their battery in a matter of minutes, but for some applications range anxiety and charge time are still a concern. One possible solution is an embedded electrical rail in the road like the [eRoadArlanda] that Sweden unveiled in 2016.

Overhead electrical wires like those used in trolleys have been around since the 1800s, and there have been some tests with inductive coils in the roadway, but the 2 km [eRoadArlanda] takes the concept of the slot car to the next level. The top of the rail is grounded while the live conductor is kept well underground beneath the two parallel slots. Power is only delivered when a vehicle passes over the rail with a retractable contactor, reducing danger for pedestrians, animals, and other vehicles.

One of the big advantages of this technology being in the road bed is that both passenger and commercial vehicles could use it unlike an overhead wire system that would require some seriously tall pantographs for your family car. Testing over several Swedish winters shows that the system can shed snow and ice as well as rain and other road debris.

Unfortunately, the project’s website has gone dark, and the project manager didn’t respond when we reached out for comment. If there are any readers in Sweden with an update, let us know in the comments!

We’ve covered both overhead wire and embedded inductive coil power systems here before if you’re interested in EV driving with (virtually) unlimited range.

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When One Cylinder Isn’t Enough: The Briggs And Stratton V8

February 28, 2023 by Jenny List 13 Comments

The Briggs & Stratton single cylinder sidevalve engine is one that has been in production in one form or another for over a century, and which remains one of the simplest, most reliable, and easiest to maintain internal combustion engines there is. The little single-cylinder can be found on lawnmowers and other similar machinery everywhere, so it’s rather easy to find yourself in possession of more than one. [Lyckebo Mekaniska] evidently had no shortage of them, because he’s produced a V8 engine for a small lawn tractor using eight of them. A small air-cooled V8 sidevalve is something of a unique engine to be made in the 2020s, and the series of videos is definitely worth a watch from start to finish. We’ve been keeping an eye on this build for a while now, and we’ve embedded it below the break for your entertainment.

A CAD view of the V8 engine — Clearly a lot of CAD work has gone into this build.

For an engine which uses mass-produced engines for its construction, this one still relies heavily on parts machined from first principles. The cylinder blocks, valves, pistons, and crank rods are Briggs & Stratton, the rest is made in the workshop. It’s a design with the valves on the outside — so instead of the single camshaft you might expect from experience with OHV engines nestling in the V above the camshaft it has two camshafts at the bottom of the crankcase.

The crankcase is cast in sections first, followed by the machining of the crankshaft and camshafts, then the preparation of the cylinders.. The engine is assembled with a home made alternator on its flywheel and a conventional distributor from a donor vehicle. The lubrication system is another work of the machinist’s art, and the simple straight-through exhaust system is more at home on a drag racer than a lawnmower. Finally we see it running, and it sounds the business. Most recently he’s had to deal with a seizure and a replacement cylinder, but now it’s back together and he’s working on an improved cooling system.

All in all this is one heck of a build, and we wish we had some of those skills. We’re not sure whether he’ll mow the lawn with this thing, but one thing’s for sure, lawnmower hacking has quite a past.

Continue reading “When One Cylinder Isn’t Enough: The Briggs And Stratton V8” →