Forming Fipples And Accompanying Accoutrements

[Dr. Suess] created memorable books with minimal words and bright artwork. He inspired children and adults alike, and one of them, [Len], grew up to create wind instruments for the Bellowphone channel on YouTube. Behind the whimsy of his creations is significant engineering, and this time, we get to see the construction of a fipple. The video is also shown after the break. Even though fipple sounds like a word [Dr. Suess] would have coined, it is a legitimate musical term that means a whistle-like mouthpiece. In this case, it blows air across glass jars to create the sound for [Len]’s bottle organ. Check out the second video below for a performance from The Magic Flute.

[Len] uses clear rigid PVC for the fipples and a custom forming die to shape them while they are soft. The rest is precision hand-tool work with a razor saw, hand file, and wet-dry sandpaper. Once complete, the fipple looks like any musical instrument part produced by exacting construction techniques. Making a mouthpiece is one thing, but if it is not directed correctly it will not make any sound, so we also learn how to turn steel strapping into an organ bottle assembly. If you add some tubing and rubber squeeze balls, you can make your own instrument.

Part of the reason the Bellowphone channel exists is that [Len] found a lot of support in the pipe organ community that showed him the secret inner workings of their livelihood and now is his chance to share that enthusiasm with the maker community.

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Spot Welding …Plastic?

Plastic milk bottles, when your project or prototype needs an urgent source of plastic, they are often the first thing to hand. Convenient and flexible, but strong at the same time and usually free, they’re the ultimate source of material in a pinch. However, when it comes to actually manipulating the HDPE plastic they’re made from, there’s often a challenge. It’s easy to cut, but not so easy to join. Conventional glues can have a hard time, making it difficult to bond.

Enter [zimitt], and a spot welding solution for joining HDPE with ease. Ok, so ‘spot welding’ might be a little optimistic given the speed of this process, but it’s useful nonetheless. To heat the plastic, a cheap soldering iron is recommended. A low wattage, straight-to-the-wall one does well, especially as they commonly have the washer-style end shown in the picture. To protect the plastic from burning, a BBQ mat is used – they’re temperature resistant and usually made with a PTFE surface.

First, place the two sheets of plastic face to face and sandwich top and bottom with the BBQ mat. Apply some heat to the mat with the soldering iron then, after a few seconds, remove the iron and provide pressure with a flat object to bond the plastic. [zimitt] used an espresso tamper for this which was ideal.

The results are impressive, and [zimitt] experiments with different plastics as well. Of course, you should exercise caution when attempting anything like this, given the health risks present when heating up different types of plastic.

HDPE is easy to recycle at home, and we’ve seen a lot of great uses: a plastic joiner’s mallet, plastic tiles, and even a filament extruder for 3D printing.

Electronic Message In A Bottle

We remember going to grandfather’s garage. There he would be, his tobacco pipe clenched between his teeth, wisps of smoke trailing into the air around him as he focused, bent over another of his creations. Inside of a simple glass bottle was something impossible. Carefully, ever so carefully, he would use his custom tools to twist wire. He would carefully place each lead. Eventually when the time was right he would solder. Finally he’d place it on the shelf next to the others, an LED matrix in a bottle.

led-message-in-a-bottle-assemblyWell, maybe not, but [Mariko Kosaka]’s father [Kimio Kosaka] has done it. In order to build the matrix, he needed tools that could reach inside the mouth of the bottle without taking up too much space to allow for precise movement. To do this he bent, brazed, twisted, and filed piano wire into tools that are quite beautiful by themselves. These were used to carefully bend and position the LEDs, wires, and other components inside the bottle.

Once the part was ready, he used a modified Hakko soldering iron to do the final combination. We wonder if he even had to be careful to solder quickly so as not to build up a residue on the inside of the bottle? The electronics are all contained inside the bottle. One of the bottles contained another impressive creation of his: an entire Arduino with only wire, dubbed the Arduino Skeleton. Batteries are attached to the cork so when the power runs low it can be removed and replaced without disturbing the creation.

It’s a ridiculous labor of love, and naturally, we love it. There’s a video of it in operation as well as one with him showing how it was done which is visible after the break. He showed them off at the Tokyo Maker Faire where they were surely a hit.

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Building A Tornado In A Bottle

vortex-tornado-machine

Recreate the look of a tornado by building this water vortex art piece. The components that go into it are all very simple and can be found in your recycling bin with the exception of a motor and a way to drive it. The hard part is going to be getting to the point where you don’t have any leaks.

[Ixisuprflyixi] went with an empty salsa bottle to house the vortex. It’s a pleasant shape for the project since it’s both tall and narrow and it’s got a bit of a sexy curve to it. The base of the machine is a plastic bottle which looks like it might have been for Metamucil, but we’re not sure.  The important part is that it needs to be made from HDPE, as a portion of the container will be used to make the impeller. That’s the part that attaches to the motor shaft inside of the container. Give it a spin and you’ve got yourself a tornado in a bottle. See it in action after the jump.

This is a much quicker and easier version than the one we saw [Ben Krasnow] build. He ended up doing some repair work on the gasket that seals the motor shaft. It’s an interesting read if you are thinking of building one of these yourself.

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Hipster Chandelier

This chandelier is something we’d expect to see on sale in the local gallery store. [Starkec] made it a couple of years back and we just love the look. The materials are pretty common, and you can throw it together in an afternoon.

The diffuser are made from clear glass soda bottles. After removing the labels and giving them a good cleaning, they were each set upside down and sprayed with some glass frosting spray. A four-conductor telephone wire serves both as the support for the bottle and electrical path for the RGB LED inside of each. The original screw cap for the bottles makes it a twist to install them after the soldering is done. There are two common color buses so that alternating colors can be shown at the same time. After seeing the video we think you’ll agree that the wiring scheme makes for some great animated effects.

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Soda Bottle Skylights

Here’s a way to brighten up enclosed spaces in an environmentally friendly way. The power of the sun is harnessed using a bottle full of water. Quite simply they’re used 2-liter soda bottles. They’ve been filled with water along with two caps worth of bleach to keep microorganisms out. The cap is then covered with a film canister to protect it from the sun. They are installed through holes in the roof, and in full sun they put out the equivalent of a 50 watt incandescent light bulb.

Our first thought is keeping the weather out but that is addressed in the video after the break. With proper weather sealing they do not leak. We might not be installing them in the house just yet, but what a great addition to that dark shed that has no electricity and seems to gobble up yard implements. Perhaps we’ll finally be able to find all of those hand trowels that have gone missing.

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Building A Better Water Rocket Launchpad

School will be starting again in a few weeks but it’s not too late to enjoy a little time with your kids. This water rocket launcher lets you do just that. Built using the frame from an old grill, a soda bottle takes its place on the upturned PVC pipe. There’s a connection for your garden hose that allows you to inject water into the bottle. From there, a compressor connection pressurizes the bottle in preparation for launch. Watch it happen in the video after the break. That bottle could use some fins and a nose cone but there’s no denying the delight the kids are enjoying when they chase after the downed craft.

If you’ve already got a compressor and some empty 2-liter bottles you might also pick up some extra PVC to make this pressurized water cannon.