Coroplast

6 Articles

Bike On Over To The Campground

March 20, 2022 by 9 Comments

Like many of us, [Paul] enjoys occasionally hitching up his tow-behind camper and heading out to the wilderness to get away from it all at his favorite campsite. Unlike the vast majority of those who share his passion for the outdoors, though, [Paul] is hitching his camper up to a bicycle. Both the camper and the bike are custom built from the ground up, and this video shows us a little more details on [Paul]’s preferred mode of transportation.

While he is known for building custom vehicles of one sort or another, this latest one is a more traditional bicycle frame that he has modified only slightly to fit a recumbent-style seat and a small gas-powered motor. Even though the motor is decades old, it started right up and gives the power needed to pull the custom camper. [Paul] builds one-person campers like this out of corrugated plastic for durability and light weight, and this one is specifically designed for his size and sleeping style. It includes everything needed for a night under the stars, too, including a stove, storage compartments, and a few windows.

With the bike and camper combined weighing in at just over 200 pounds, the motor can be used as a pedal-assist device thanks to the clever engineering behind a front-wheel-drive pedal system on this bike. With all of that custom fabrication, [Paul] is free to head out to the wilderness without all the encumbrances (and high price) of traditional motor vehicle-based camping. For those curious about some of [Paul]’s other vehicle creations, take a look at this tiny speedboat for one.

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Art of 3D printer in the middle of printing a Hackaday Jolly Wrencher logo

3D Printering: Corrugated Plastic For Cheaper & Easier Enclosures

October 6, 2021 by 37 Comments

Clear acrylic panels have long been a mainstay of 3D printer enclosure designs, but they can also add significant cost in terms of money, shipping, weight, and hassle. An alternative material worth looking at is corrugated plastic (also known by its trade name coroplast) which is cheap, light, an excellent insulator, and easy to work with. Many enclosure designs can be refitted to use it instead of acrylic, so let’s take a closer look at what it has to offer.

What’s Wrong With Acrylic?

It’s not just the purchase price that makes acrylic a spendy option. Acrylic is fairly heavy, and shipping pieces the size of enclosure panels can be expensive. Also, cutting acrylic without special tools can be a challenge because it cracks easily if mishandled. Acrylic cuts beautifully in a laser cutter, but most laser cutters accessible to a hobbyist are not big enough to make enclosure-sized panels. If you are stuck with needing to cut acrylic by hand, here are some tips on how to get by with the tools you have.

It is best to source acrylic from a local shop that can also cut it to size with the right tools for a reasonable price, but it is still far from being a cheap material. There’s another option: corrugated plastic has quite a few properties that make it worth considering, especially for a hobbyist.

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How An Engineer Designs A DIY Energy Recovery Ventilator

October 21, 2020 by 80 Comments

We have no idea whether [Nick Goodey] is a trained engineer or not. But given the detailed design of this DIY energy recovery ventilator for his home HVAC system, we’re going to go out on a limb and say he probably knows what he’s doing.

For those not in the know, an energy recovery ventilator (ERV) is an increasingly common piece of equipment in modern residential and commercial construction. As buildings have become progressively “tighter” to decrease heating and cooling energy losses to the environment, the air inside them has gotten increasingly stale. ERVs solve the problem by bringing fresh, unconditioned air in from the outside while venting stale but conditioned air to the outside. The two streams pass each other in a heat exchanger so that much of the energy put into the conditioned air is transferred to the incoming unconditioned air.

While ERV systems are readily available commercially, [Nick] decided to roll his own after a few experiments with Coroplast and some extensive calculations convinced him it would be a viable idea. One may scoff at the idea of corrugated plastic for the heat exchanger, but the smooth channels through the material make it a great choice. He built up a block of Coroplast squares with the channels in alternate layers oriented orthogonally, letting stale inside air pass very close to fresh outside air to exchange heat without ever mixing directly. The entire system, including fans, an Arduino for control, sensors galore, and the Hubitat home automation hub, is powered by DC, so no electrician was needed. [Nick] has a ton of detail in his build log, including all the tools and calculators he used to design the system.

Given the expense of ERV systems, we’re surprised we haven’t seen more stories about DIY versions. We have talked about HVAC systems a lot, though — after all, HVAC techs are hackers who make housecalls.

DIY Plastic Speedboat For One

June 17, 2020 by 32 Comments

Coroplast (short for corrugated plastic) is an interesting material. It has a structure similar to cardboard, but since it’s plastic it’s waterproof and can be used for a unique set of applications. It’s typically used for political yard signs, but there are more fun things to do with this lightweight material than advertise. [Paul Elkins], for example, uses it to make speedboats.

The boats that [Paul] builds make use of a piece of coroplast which he cuts and folds into a basic hull shape. From there he begins to assemble the other things needed to finalize the boat, including strengthening the shape with wood, adding a steering wheel, building a transom to mount the motor to, and placing controls in the cockpit such as throttle and steering. The entire build is enough to propel a single person on a body of water at about five knots, which is impressive.

To make one of these yourself you’ll need a small outboard motor, but all of the other details of the build are outlined clearly in his series of videos. If you want to build your own boat but don’t like the idea of a noisy two-stroke motor right behind you, you can also look into building a boat with a silent mode of propulsion.

And if you’ve got a good supply of Coro, definitely check out [Paul]’s other projects, including a tiny house.

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Hackaday Links: September 18, 2016

September 18, 2016 by 25 Comments

No Star Trek until May, 2017, at which time you’ll have to pay $5/month to watch it with ads. In the meantime, this is phenomenal and was shut down by Paramount and CBS last year ostensibly because Star Trek: Discovery will be based around the same events.

Tempest in a teacup. That’s how you cleverly introduce the world’s smallest MAME cabinet. This project on Adafruit features a Pi Zero, a 96×64 pixel color OLED display, a few buttons, a tiny joystick, and a frame made out of protoboard. It’s tiny — the height of this cabinet just under two wavelengths of the radiation corresponding to the transition between the two hyperfine levels of the ground state of the cesium 133 atom. Being based on the Pi Zero, it’s a capable arcade cabinet, although we would struggle to find a continuous rotation pot small enough to play Tempest the way it should be played. Check out the video.

[Graham] sent an interesting observation in on the tip line. It’s an election year in the US, and that can mean only one thing. It’s coroplast season. Coroplast is that strange material used for political signage, famous for its light weight, being waterproof, and reasonably strong, depending on how you bend it. There is a severe lack of coroplast builds, but if you have some be sure to send them in.

The ESP32, the followup to the hugely popular ESP8266 , is shipping. [Elliot] got his hands on one and found it to be a very promising chip, but the ESP3212 modules I bought from Seeed haven’t arrived yet. That hasn’t stopped [Ptwdd] from making a breakout board for the ESP3212, though. We don’t know if it works, but it’s just a breakout board, anyway.

The usual arguments for drones involve remote sensing, inspection, and generally flying around for a very long time. Quadcopters don’t do this, but fixed wings can. Over on DIYDrones, [moglos] just flew 425km on a single charge. The airframe is a 3 meter Vigilant C1 V tail, using the stock 300kV motor. The battery is a bunch of Panasonic 18650 cells arranged in 6S 9P configuration for 30600mAh. The all-up weight is 5.7kg. This is significant, and we’re seeing the first glimmer of useful tasks like pipeline monitoring, search and rescue, and mapping being done with drones. It is, however, less than half the range a C172 can fly, but batteries are always getting better. Gas goes further because it gets lighter as you fly.

Hackaday Links: April 3, 2016

April 3, 2016 by 27 Comments

April Fool’s Day was last Friday, and the Internet was garbage for a day. Our April Fool’s prank was amazing, and in a single day garnered more views than the Raspberry Pi 3 launch announcement from a month prior. There just might be a market here for Apple. Here’s a short roundup of some of the best electronics April Fool’s posts:

This, surprisingly, was not an April Fool’s post. [Dave Jones] has been looking to upgrade his workspace for a few years now. He’s finally found a place. It’s the old Altium office in Sydney. [Dave] worked at Altium before spinning up the EEVblog, so this really is his old stomping grounds. It’s 4000 square meters (43,000 square feet), and exactly 3950 square meters larger than his current lab. What is he going to do with all that space? He’s looking for suggestions, but I would suggest an awesome model train layout. A [Dave Haynie]-style tour would also be acceptable.

Yesterday was the unofficial geekhack / deskthority / r/mechanicalkeyboards SoCal Mechanical Keyboard meetup at Datamancer in Montclair, CA. I was there, got a Control key to replace the Caps Lock key on my Novatouch, and took a lot of pictures.

It’s a presidential election year in the US, and that means millions of people are going to make America great again by polluting their front yard with campaign signs. These campaign signs are usually made out of coroplast, a material that looks like corrugated cardboard, but is made out of dead dinosaurs instead of dead trees. Coroplast is a very interesting material, and [uminded] tipped us off to some guy that makes mini speedboats in this rather uncommon material.

There are some things you just shouldn’t do. Combining octocopters with chainsaws, for example. You shouldn’t do it, but someone will anyway, and YouTube exists. Here’s an octocopter with a chainsaw.

Foxconn is buying Sharp. Sharp has a rather large portfolio of LEDs and optoelectronics, but this deal is mostly for Sharp’s large contract manufacturing business.