Need A Night-Light?

September 19, 2017 by Lauren Faris 36 Comments

[Scott] created an LED candle in preparation for the big mac daddy storm (storms?) coming through. Like millions of other people in Florida, he was stuck at home with his roommates when an oncoming hurricane headed their way. Worrying about blundering about in the dark when the power inevitably went out, they set off to gather up all of the candles they had lying around. Realizing the monstrous pile of candles and matches looked more and more like a death wish, the decision was made to create a makeshift light out of what components they had on hand. Now, not having access to any outside sources for parts means that you are going to have a bare bones model.

That being said, this straightforward light only takes a couple of seconds to put together. Jury rig a couple of AA or AAA batteries up, then slap on a resistor, LED, and jumper to get that sucker running. Wrap electrical tape around the whole thing, or even try duct tape, whatever gets the job done. A little paper hat on top of it will diffuse the light and bada bing, bada boom, you’re all done. Generally though, soldering directly onto a battery is not a wise idea. So, if you want to get fancy, perhaps a better alternative is to have a battery casing as shown below.

This LED candle is a clear option if your home isn’t a micro warehouse for electronic components (apparently it is frowned upon to clog up your garage for projects), and you have limited time. However, if you have a number of extra minutes lying around before your windows blow in, see if you can top the brightest flashlight ever made (thus far). Continue reading “Need A Night-Light?” →

A Battery-Tab Welder With Real Control Issues

September 16, 2017 by Dan Maloney 56 Comments

Spot welding should easier than it looks. After all, it’s just a lot of current in a short time through a small space. But it’s the control that can make the difference between consistently high-quality welds and poor performance, or maybe even a fire.

Control is where [WeAreTheWatt]’s next-level battery tab spot welder shines. The fact that there’s not a microwave oven transformer to be seen is a benefit to anyone sheepish about the usual mains-powered spot welders we usually see, even those designed with safety in mind. [WeAreTheWatt] chose to power his spot welder from a high-capacity RC battery pack, but we’d bet just about any high-current source would do. The controller itself is a very sturdy looking PCB with wide traces and nicely machined brass buss bars backing up an array of MOSFETs. A microcontroller performs quite a few functions; aside from timing the pulse, it can control the energy delivered, read the resistance of the 8AWG leads for calibration purposes, and even detect bad welds. The welder normally runs off a foot switch, but it can also detect when the leads are shorted and automatically apply a pulse — perfect for high-volume production. See it in action below.

There may be bigger welders, and ones with a little more fit and finish, but this one looks like a nicely engineered solution.

Continue reading “A Battery-Tab Welder With Real Control Issues” →

This Electric Longboard Collapses For Air Travel

September 8, 2017 by Dan Maloney 26 Comments

How do you manage to get an electric off-road longboard past TSA and onto an international flight? Simple — make it a collapsible longboard that fits into a carry-on bag.

The mechanical and electrical feats accomplished by [transistor-man] may not be the most impressive parts of this hack. We’re pretty impressed by the build, starting as it did with the big knobby tires and front truck from an unused mountain board and the hub motor from a hoverboard, turning this into a trike. The incredible shrinking chassis comes courtesy of a couple of stout drawer slides and cam locks to keep it locked in place; collapsed, the board fits in a carry on bag. Expanded, it runs like a dream, as the video below shows.

But we think the really interesting part of this hack is the social engineering [transistor-man] did to ensure that the authorities wouldn’t ground his creation for electrical reasons. It seems current rules limit how big a battery can be and how many of them can be brought on a flight, so there was a lot of battery finagling before his creation could fly.

Electric longboards look like a real kick, whether they be all-aluminum or all-plastic, or even all-LEGO. This one, which went from concept to complete a week and a half before the flight, really raises the bar.

Continue reading “This Electric Longboard Collapses For Air Travel” →

How Low-Power Can You Go?

September 1, 2017 by James Hobson 28 Comments

[lasersaber] has a passion: low-power motors. In a bid to challenge himself and inspired by betavoltaic cells, he has 3D printed and built a small nuclear powered motor!

This photovoltaic battery uses fragile glass vials of tritium extracted from keychains and a small section of a solar panel to absorb the light, generating power. After experimenting with numerous designs, [lasersaber] went with a 3D printed pyramid that houses six coils and three magnets, encapsulated in a glass cloche and accompanied by a suitably ominous green glow.

Can you guess how much power and current are coursing through this thing? Guess again. Lower. Lower.

Under 200mV and 20nA!

Continue reading “How Low-Power Can You Go?” →

An Environmentally Conscious, Solar-Powered Throwie

September 1, 2017 by James Hobson 24 Comments

The basic throwie is a a type of street art/graffiti/vandalism — depending on where you stand — consisting of a coin cell, an led, and a magnet taped together. Seeking to be a slightly more eco-friendly troublemaker, [Alaric Loftus] has kindly put together an Instructable on how to build a solar-powered throwie!

In order to be the best maker of mischief possible, [Alaric Loftus] tried a number of different products to find one that was hackable, supplied the right voltage, had the right form factor, and cheap enough to literally throw away. Turns out, garden path lights hit that sweet spot. Once [Alaric Loftus] has drilled a hole in the light and opened it up, de-soldering the stock LED, attaching some leads to the contacts and sticking it into the freshly-drilled hole is simply done. Hot-gluing a strong magnet on the bottom completes the throwie.

[Alaric Loftus] also advises that drilling the LED hole slightly smaller and sealing up any cracks with hot glue will strengthen its water resistance — because if it’s worth doing, it’s worth doing it right.

We’ve featured some really cool — even creepy — takes on the throwie concept, but please don’t contribute any further to e-waste buildup.

Blast Your Battery’s Sulphates, Is It Worth It?

August 25, 2017 by Jenny List 55 Comments

When a friend finds her caravan’s deep-cycle battery manager has expired over the summer, and her holiday home on wheels is without its lighting and water pump, what can you do? Faced with a dead battery with a low terminal voltage in your workshop, check its electrolyte level, hook it up to a constant current supply set at a few hundred mA, and leave it for a few days to slowly bring it up before giving it a proper charge. It probably won’t help her much beyond the outing immediately in hand, but it’s better than nothing.

A lot of us will own a lead-acid battery in our cars without ever giving it much thought. The alternator keeps it topped up, and every few years it needs replacing. Just another consumable, like tyres or brake pads. But there’s a bit more to these cells than that, and a bit of care and reading around the subject can both extend their lives in use and help bring back some of them after they have to all intents and purposes expired.

One problem in particular is sulphation of the lead plates, the build-up of insoluble lead sulphate on them which increases the internal resistance and efficiency of the cell to the point at which it becomes unusable. The sulphate can be removed with a high voltage, but at the expense of a dangerous time with a boiling battery spewing sulphuric acid and lead salts. The solution therefore proposed is to pulse it with higher voltage spikes over and above charging at its healthy voltage, thus providing the extra kick required to shift the sulphation build up without boiling the electrolyte.

If you read around the web, there are numerous miracle cures for lead-acid batteries to be found. Some suggest adding epsom salts, others alum, and there are even people who talk about reversing the charge polarity for a while (but not in a Star Trek sense, sadly). You can even buy commercial products, little tablets that you drop in the top of each cell. The problem is, they all have the air of those YouTube videos promising miracle free energy from magnets about them, long on promise and short on credible demonstrations. Our skeptic radar pings when people bring resonances into discussions like these.

So so these pulse desulphators work? Have you built one, and did it bring back your battery from the dead? Or are they snake oil? We’ve featured one before here, but sadly the web link it points to is now only available via the Wayback Machine.

Possibly The Most Up-Cycled, Hacked E-Bike You’ll See All Week

August 24, 2017 by Donald Papp 32 Comments

When it comes to bringing an idea to life it’s best to have both a sense of purpose, and an eagerness to apply whatever is on hand in order to get results. YouTube’s favorite Ukrainians [KREOSAN] are chock full of both in their journey to create this incredible DIY e-bike using an angle grinder with a friction interface to the rear wheel, and a horrifying battery pack made of cells salvaged from what the subtitles describe as “defective smartphone charging cases”.

Battery pack made from cells salvaged out of defective equipment. Sometimes, you use what you have on hand.

What’s great to see is the methodical approach taken to creating the bike. [KREOSAN] began with an experiment consisting of putting a shaft on the angle grinder and seeing whether a friction interface between that shaft and the tire could be used to move the rear wheel effectively. After tweaking the size of the shaft, a metal clamp was fashioned to attach the grinder to the bike. The first test run simply involved a long extension cord. From there, they go on to solve small problems encountered along the way and end up with a simple clutch system and speed control.

The end result appears to work very well, but the best part is the pure joy (and sometimes concern) evident in the face of the test driver as he reaches high speeds on a homemade bike with a camera taped to his chest. Video is embedded below.

Continue reading “Possibly The Most Up-Cycled, Hacked E-Bike You’ll See All Week” →