Cutting Stone with a Diamond Bit Built from Plumbing parts

Everyone’s favorite Canadian is at it again. This time, [AVE] needed to cut a large hole in a stone countertop. They making coring bits for this, but a bit this size would cost upwards of $400. Not a problem. [AvE] broke out the tools and built his own stone cutting bit.

Everything starts with a 6″ plastic pipe cap. [AvE] center drilled the cap, then threaded it. A turned down bolt makes a great arbor for this new tool. The edge of the cap was then slotted. [AvE] used a clapped out Bridgeport milling machine, but you could do the same job with a hacksaw or a Dremel tool.

The secret sauce is industrial diamonds. That’s right, this is a diamond cutting bit. [AvE] ordered 20 grams of 20-25 mesh industrial diamonds. “Mesh” defines the size of the individual diamonds — in this case around 50 microns and up.  Now, how to bind diamond and plastic? Plumber’s transition cement didn’t work – the diamonds and coating just peeled off like a sunburn. The solution turned out to be JB-Weld. A liberal coating of JB-Weld on the face of the tool, a sprinkling of industrial diamonds, and the pipe cap was ready to cut.

The cutting operation was slow, steady, and lots of cooling water. [AvE] made it most of the way through his countertop before having to refurbish his bit.

[AvE] usually is a man of many words, as can be seen in this post about his EDM machine. This time though, he gave us the silent treatment — an entire video with no words, set to classical music. It’s great seeing YouTubers step outside their comfort zone and trying something new.

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Under the Hood of AMD’s Threadripper

Although AMD has been losing market share to Intel over the past decade, they’ve recently started to pick up steam again in the great battle for desktop processor superiority. A large part of this surge comes in the high-end, multi-core processor arena, where it seems like AMD’s threadripper is clearly superior to Intel’s competition. Thanks to overclocking expert [der8auer] we can finally see what’s going on inside of this huge chunk of silicon.

The elephant in the room is the number of dies on this chip. It has a massive footprint to accommodate all four dies, each with eight cores. However, it seems as though two of the cores are deactivated due to a combination of manufacturing processes and thermal issues. This isn’t necessarily a bad thing, either, or a reason not to use this processor if you need to utilize a huge number of cores, though; it seems as though AMD found it could use existing manufacturing techniques to save on the cost of production, while still making a competitive product.

Additionally, a larger die size than required opens the door for potentially activating the two currently disabled chips in the future. This could be the thing that brings AMD back into competition with Intel, although both companies still maintain the horrible practice of crippling their chips’ security from the start.

Custom Aluminum Wheels Teach a Thing or Two about Casting

For some mobile projects like small carts or rolling cabinets, your standard casters from Harbor Freight will do just fine. But some projects need big, beefy wheels, and these custom cast aluminum wheels certainly make a statement. Mostly, “Watch your toes!”

To be honest, [Brian Oltrogge]’s wheels are an accessory in search of a project, and won’t be crushing feet anytime soon. He made them just to make them, but we have no beef with that. They’ve got a great look that hearkens back to a time when heavy metal meant something else entirely, and things were made to last. Of course, being cast from aluminum sort of works against that, but there are practical limits to what can be done in the home foundry. [Brian] started with a session of CAD witchcraft followed by machining the cores for his molds. Rather than doing this as lost foam or PLA, he milled the cores from poplar wood. His sand mix is a cut above what we usually see in home-brew sand casting — sodium silicate sand that can be cured with carbon dioxide. All his careful preparation meant the pour went off without a hitch, and the wheels look great.

We’ve featured quite a few metal casting projects recently, some that went well and some that didn’t. [Brian] looks like he knows what he’s doing, and we appreciate the workmanship that he puts on display here.

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Custom Engine Parts from a Backyard Foundry

Building a car engine can be a labor of love. Making everything perfect in terms of both performance and appearance is part engineering and part artistry. Setting your creation apart from the crowd is important, and what better way to make it your own than by casting your own parts from old beer cans?

[kingkongslie] has been collecting parts for a dune buggy build, apparently using the classic VW Beetle platform as a starting point. The air-cooled engine of a Bug likes to breathe, so [kingkongslie] decided to sand-cast a custom crankcase breather from aluminum.

Casting solid parts is a neat trick but hardly new; we’ve covered the techniques for casting plastic, pewter, and even soap. The complexity of this project comes from the fact that the part needs to be hollow. [kingkongslie] managed this with a core made of play sand and sodium silicate from radiator stop-leak solution hardened with a shot of carbon dioxide. Sure, it looks like a Rice Krispie treat, but a core like that will stand up to the molten aluminum while becoming weak enough to easily remove later. The whole complex mold was assembled, beer cans melted in an impromptu charcoal and hair-dryer foundry, and after one false start, a shiny new custom part emerged from the sand.

We’ve got to hand it to [kingkongslie] – this was a nice piece of work that resulted in a great looking part. But what we love about this is not only all the cool casting techniques that were demonstrated but also the minimalist approach to everything. We can all do stuff like this, and we probably should.

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Thanks for the Memories: Touring the Awesome Random Access of Old

I was buying a new laptop the other day and had to make a choice between 4GB of memory and 8. I can remember how big a deal it was when a TRS-80 went from 4K (that’s .000004 GB, if you are counting) to 48K. Today just about all RAM (at least in PCs) is dynamic–it relies on tiny capacitors to hold a charge. The downside to that is that the RAM is unavailable sometimes while the capacitors get refreshed. The upside is you can inexpensively pack lots of bits into a small area. All of the common memory you plug into a PC motherboard–DDR, DDR2, SDRAM, RDRAM, and so on–are types of dynamic memory.

The other kind of common RAM you see is static. This is more or less an array of flip flops. They don’t require refreshing, but a static RAM cell is much larger than an equivalent bit of dynamic memory, so static memory is much less dense than dynamic. Static RAM lives in your PC, too, as cache memory where speed is important.

For now, at least, these two types of RAM technology dominate the market for fast random access read/write memory. Sure, there are a few new technologies that could gain wider usage. There’s also things like flash memory that are useful, but can’t displace regular RAM because of speed, durability, or complex write cycles. However, computers didn’t always use static and dynamic RAM. In fact, they are relatively newcomers to the scene. What did early computers use for fast read/write storage?

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Toroid winding cheat

When you need a toroid the easiest source is often to wind it yourself. The problem being that placing a few hundred windings around a ferrite ring is a real drag, especially if you have to make several of them. This cheat developed by [Jim W.] will save a lot of time. He cuts the ring in half for the winding and reassembles it afterward.

Here you can see that he has half of the core mounted in a drill chuck. To get to this point he scored the ferrite before clamping half in a vice and whacking the extruding half with a block of wood and a hammer. He hasn’t found a perfect solution for scoring the material (a utility knife or a triangular file both work but have drawbacks). Leave a comment if you’ve got any bright ideas.

Once the core is in two pieces he used some copper pipe with one end flattened and bent to the shape of the ring segment. With it hot glued in place he takes it for a spin (shown in the clip after the break). Once the windings are done a bit of super glue recombines the halves. This sort of thing is great for monitoring power use.

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