Making A Guitar Go To Eleven, The Hard Way

December 21, 2023 by Dan Maloney 10 Comments

At the end of the day, all it takes to make a guitar go to eleven is a new knob. Making the knob is another thing — that takes a shop full of machine tools, the expertise to use them, and a whole bunch of time. Then again, if you’re pressed for time, it looks like a 3D printer will do nicely too.

While the 3D printing route is clearly the easier option, it sure seems as if [Chronova Engineering] is more about the journey than the destination. In need of some knob bling for an electric guitar, he takes us through the lengthy process (nicely summarized in the video below) of crafting one from a bar of solid brass. Like all good machining projects, this one starts with making the tools necessary to start the actual build; in this case, it’s a tool to cut the splines needing to mate with the splines on the guitar’s potentiometer shaft. That side quest alone represents probably a third of the total effort on this project, and results in a tool that’s used for all of about 30 seconds.

Aside from spline cutting, there are a ton of interesting machining tidbits on display here. We particularly liked the use of a shaping technique to form the knurling on the knob, as opposed to a standard rotary method, which would have been difficult given the taper on the knob body. Also worth noting are the grinding step that puts a visually interesting pattern on the knob’s top surface, as well as the pantograph used to etch the knob’s markings.

Congrats to [Chronova Engineering] for a great-looking build, and the deep dive into the machinist’s ways. If you’re still interested in custom brass knobs but don’t have a machine shop, we can help with that.

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Stripped Clock Wheel Gets A New Set Of Teeth, The Hard Way

March 29, 2023 by Dan Maloney 14 Comments

If there’s one thing we’ve learned from [Chris] at Clickspring, it’s that a clockmaker will stop at nothing to make a clock not only work perfectly, but look good doing it. That includes measures as extreme as this complete re-toothing of a wheel from a clock. Is re-toothing even a word?

The obsessive horologist in this case is [Tommy Jobson], who came across a clock that suffered a catastrophic injury: a sudden release of energy from the fusee, the cone-shaped pulley that adjusts for the uneven torque created by the clock’s mainspring. The mishap briefly turned the movement into a lathe that cut the tops off all the teeth on the main wheel.

Rather than fabricate a completely new wheel, [Tommy] chose to rework the damaged one. After building a special arbor to hold the wheel, he turned it down on the lathe, leaving just the crossings and a narrow rim. A replacement blank was fabricated from brass and soldered to the toothless wheel, turned to size, and given a new set of teeth using one of the oddest lathe setups we’ve ever seen. Once polished and primped, the repair is only barely visible.

Honestly, the repaired wheel looks brand new to us, and the process of getting it to that state was fascinating to watch. If the video below whets your appetite for clockmaking, have we got a treat for you.

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Brass Plaque Honors Brother

August 3, 2022 by Brian McEvoy 10 Comments

Brass plaques are eye-catching because no one makes them on a whim. They are more costly than wood or plastic, and processing them is proportionally difficult. [Becky Stern] picked the medium to honor her brother, who enjoyed coffee, motorcycles, and making things by hand. She made some playing card-sized pieces to adorn his favorite brand of hot bean juice and a large one to hang at his memorial site.

The primary components are a vertical salt water bath, DC power supply, metal to etch, scrap steel approximately the same size, and a water agitator, which in this case is an air pump and diffuser stone. You could stir manually for two hours and binge your shows but trust us and take the easy route. The video doesn’t explicitly call for flexible wires, but [Becky] wisely selected some high-strand hook-up leads, which will cause fewer headaches as stiff copper has a mind of its own, and you don’t want the two sides colliding.

There are a couple of ways to transfer an insulating mask to metal, and we see the ole’ magazine paper method fail in the video, but cutting vinyl works a treat. You may prefer lasers or resin printers, and that’s all right too. Once your mask is sorted, connect the positive lead to the brass and the negative to your steel. Now, it’s into the agitated salt water bath, apply direct current, and allow electricity to immortalize your design.

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Barely HDMI Display Gets A Steampunk-Inspired Enclosure

May 13, 2022 by Dan Maloney 21 Comments

It’s an interesting question: What does one do for a follow-up to building the world’s worst HDMI display? Simple — stick it in a cool steampunk-inspired case and call it a day.

That seems to have been [mitxela]’s solution, and please don’t take our assessment as a knock on either the original build or this follow-up. [mitxela] himself expresses a bit of wonder at the attention garnered by his “rather stupid project,” which used the I2C interface in an HDMI interface to drive a tiny monochrome OLED screen. Low refresh rate, poor resolution — it has everything you don’t want in a display, but was still a cool hack that deserved the attention it got.

The present work, which creates an enclosure for the dodgy display, is far heavier on metalworking than anything else, as the video below reveals. The display itself goes in a small box that’s machined from brass, while the HDMI plug gets a sturdy-looking brass housing that makes the more common molded plastic plug look unforgivably flimsy — hot glue notwithstanding. Connecting the two is a flexible stalk, allowing it to plug into a computer’s HDMI port and giving the user the flexibility to position the nearly useless display where it can be seen best.

But again, we may be too harsh in our judgment; while DOOM is basically unplayable on the tiny display, “Bad Apple!!” is quite watchable, especially when accompanied by [mitxela]’s servo-controlled MIDI music box. And since when has usability been a criterion for judging a hack’s coolness, anyway?

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Hand-Built Metal Mouse Is Beautifully Engraved

April 26, 2022 by Lewin Day 19 Comments

Computer mice, like computers themselves, used to be built almost solely in hideous beige designs. These days, things are a bit more stylish, but they’re still largely following a simple plastic formula. [Uri Tuchman] decided to build a fancy metal engraved computer mouse for a little more style on the desktop.

The build starts by gutting a simple three-button scroll mouse, as there’s really no sense in reinventing the wheel where the electronics is concerned. The PCB inside is pulled out and assembled on a brass baseplate, along with standoffs and supports for the mouse wheel as needed. It’s paired with a hefty brass enclosure with a nice gentle slope to sit well in the hand. Or, as well as it can, given the square metal edges of the finished product.

The build is full of fun details, like [Uri] trying to form a hex shaft by hand, and the work that goes into the engraving is similarly impressive. In any case, it’s a build that would pair wonderfully with a proper steampunk keyboard. Alternatively, if you hate the idea of having to do all that engraving by hand, think about building your own CNC machine. Video after the break.

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Building A Custom Branding Iron With Swappable Date Blocks

December 17, 2021 by Lewin Day 6 Comments

Branding can be done on wood with just about any old bit of hot metal, but if you want to do it well, properly-crafted tooling will go a long way. [Wesley Treat] has built just that with this modular branding iron design.

The branding tooling itself is machined out of brass on an X-Carve CNC router, using [Wesley]’s own logo. The part is sanded after machining to remove tooling marks. A smaller brass slug is then machined with the numerals for various years with which [Wesley] may wish to stamp his projects.

Rather than hacking something sloppy together, the iron itself is assembled with a beautifully wood-turned handle of his own creation and a steel backing plate to hold the tooling. The date is separately removable from the main logo itself for easy changes in future. Naturally, the tool graphics are done in reverse so as to register the right way around when burned onto wood.

The tool is used with a torch to heat the brass up such that it can leave its impression on wooden surfaces. The final results are solid, if not quite perfect; getting the temperature across the tool perfectly matched would be key to getting the cleanest results. An electric heating element running in closed loop could be a way to achieve this.

Fundamentally, it’s a tidy way to mark your wooden projects in a hurry. We’ve seen wood burning reach even greater heights, too, such as with this CNC pyrography machine. Video after the break.

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Brass screen is soldered together into a large mold for cardboard pulp.

How To Make A Classy, Brassy Cardboard Pulp Mold

November 17, 2021 by Kristina Panos 4 Comments

When we last checked in with prolific prototypist [Eric Strebel], he was perfecting the design of an eco-friendly wireless charger and turning his initial paper prototype into a chipboard version 2.0 that takes manufacturing concerns into consideration. At the end of this second video in a series, [Eric] was printing out the early versions of the form by which he would eventually make a brass screen mold for working with cardboard pulp. You know, the stuff that some egg cartons are made from.

In the video below, it’s time to build the pulp mold by creating three smaller molds and then joining them into one horizontal mold. The result is a single piece that then gets folded up into a charging stand, much like the egg carton. [Eric] is using brass screen here, but says that copper would be a good choice, too.

After cutting the brass with scissors and pounding them flat, he uses the 3D-printed molds from the previous video to press them into the correct shapes. Each of the three pieces needs a frame, which [Eric] makes from more brass screen, then stitches it to the mold piece with loose screen threads before securing the unions with solder.

Since the weight of all the water would likely bend the brass out of shape, [Eric] finished off the mold by soldering on a frame of flat brass strip. Check out this awesome process below, and stay tuned for the next video when [Eric] pulps some cardboard and pumps out some eco-friendly chargers.

Does this look too complicated? You could always skip the whole mesh mold thing and shape your cardboard confetti directly into 3D printed parts.

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