These DIY Super Headphones Take Sound Seriously

[Pete Lewis] from SparkFun takes audio and comfort seriously, and recently shared details on making a customized set of Super Headphones, granting quality sound and stereo ambient passthrough, while providing hearing protection at the same time by isolating the wearer from the environment.

Such products can be purchased off the shelf (usually called some variant of “electronic hearing protection”), but every hacker knows nothing beats some DIY to get exactly the features one wants. After all, off-the-shelf solutions are focused on hearing protection, not sound quality. [Pete] also wanted features like the ability to freely adjust how much ambient sound was mixed in, as well as the ability to integrate a line-level audio source or Bluetooth input.

Early prototype of Super Headphones (click to enlarge)

On the surface the required components are straightforward, but as usual, the devil is in the details. Microphone selection, for example, required a lot of testing. A good microphone needed to be able to deal with extremely loud ambient sounds without distortion, yet still be sensitive enough to be useful. [Pete] found a good solution, but also muses that two sets of microphones (one for loud environments, and one for quieter) might be worth a try.

After several prototypes, the result is headphones that allow safe and loud band practice in a basement as easily as they provide high-quality music and situational awareness while mowing the lawn. Even so, [Pete]’s not done yet. He’s working on improving comfort by using photogrammetry to help design and 3D print custom-fitted components.

Beautifully Rebuilding A VR Headset To Add AR Features

[PyottDesign] recently wrapped up a personal project to create himself a custom AR/VR headset that could function as an AR (augmented reality) platform, and make it easier to develop new applications in a headset that could do everything he needed. He succeeded wonderfully, and published a video showcase of the finished project.

Getting a headset with the features he wanted wasn’t possible by buying off the shelf, so he accomplished his goals with a skillful custom repackaging of a Quest 2 VR headset, integrating a Stereolabs Zed Mini stereo camera (aimed at mixed reality applications) and an Ultraleap IR 170 hand tracking module. These hardware modules have tons of software support and are not very big, but when sticking something onto a human face, every millimeter and gram counts.

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How Hardware Testing Got Plugged Into A Continuous Integration Framework

The concept of Continuous Integration (CI) is a powerful tool in software development, and it’s not every day we get a look at how someone integrated automated hardware testing into their system. [Michael Orenstein] brought to our attention theĀ Hardware CI Arena, a framework for doing exactly that across a variety of host OSes and microcontroller architectures.

The Hardware CI Arena allows testing software across a variety of hardware boards such as Arduino, RP2040, ESP32, and more.

Here’s the reason it exists: while in theory every OS and piece of hardware implements things like USB communications and device discovery in the same way, in practice that is not always the case. For individual projects, the edge cases (or even occasional bugs) are not much of a problem. But when one is developing a software product that aims to work seamlessly across different hardware options, such things get in the way. To provide a reliable experience, one must find and address edge cases.

The Hardware CI Arena (GitHub repository) was created to allow automated testing to be done across a variety of common OS and hardware configurations. It does this by allowing software-controlled interactions to a bank of actual, physical hardware options. It’s purpose-built for a specific need, but the level of detail and frank discussion of the issues involved is an interesting look at what it took to get this kind of thing up and running.

The value of automatic hardware testing with custom rigs is familiar ground to anyone who develops hardware, but tying that idea into a testing and CI framework for a software product expands the idea in a useful way. When it comes to identifying problems, earlier is always better.

Cart Cruises Abandoned California Rail

Southern California is known for its nearly perfect year-round climate, excellent surf, and extremely high cost of living, but once you get away from the coast things are radically different. Rural California has huge tracts of land run by the Bureau of Land Management (BLM), which is publicly accessible to anyone willing to venture into the deserts. There’s not much in the way of infrastructure out there, but [Ryan] does have a unique way of traveling through it using abandoned railroad lines and this custom rail cart.

The frame of this cart is simple enough, it’s little more than 2×3 framing with a plywood deck. Some extra support is added for the motor mount and for the seating location. It uses slightly longer go-kart axles to accommodate the width of the railroad, and a small six horsepower gas engine with a single gear to power the rear axle. There are no brakes other than the riders’ shoes, and while this all seems straightforward enough the real hack here is [Ryan]’s custom wheels. He found that steel or cast wheels were not particularly comfortable on long journeys so after a few attempts he has come up with a home-built polyurethane wheel which is cast in a mold around a steel go-cart wheel and then trimmed on a lathe.

For pure exploration, there’s almost no better place to go than the American west thanks to all the public BLM land available. In this cart, you can explore long distances using an extremely low-cost method of transportation. We’ve added another video of [Ryan] exploring this area below the break to show the cart being used, too, but if you’d like a more multipurpose vehicle to use on abandoned rail near you, take a look at this bicycle which is converted to operate on the railroad.

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How To Roll Your Own Custom Object Detection Neural Network

Real-time object detection, which uses neural networks and deep learning to rapidly identify and tag objects of interest in a video feed, is a handy feature with great hacker potential. Happily, it’s also possible to make customized CNNs (convolutional neural networks) tailored for one’s own needs, and that process just got easier thanks to some new documentation for the Vizy “AI camera” by Charmed Labs.

Raspberry Pi-based Vizy camera

Charmed Labs has been making hacker-friendly machine vision devices for a long time, and the Vizy camera impressed us mightily when we checked it out last year. Out of the box, Vizy has a perfectly functional object detector application that runs locally on the device, and can detect and tag many common everyday objects in real time. But what if that default application doesn’t quite meet one’s project needs? Good news, because it’s possible to create a custom-trained CNN, and that process got a lot more accessible thanks to step-by-step examples of training a model to recognize hands doing rock-paper-scissors.

Person and cat with machine-generated tags identifying them
Default object detection works well, but sometimes one needs custom results.

The basic process is this: Start with a variety of images that show the item of interest. Then identify and label the item of interest in each photo. These photos (a “training set”) are then sent to Google Colab, which will be used to generate a neural network. The resulting CNN model can then be downloaded and used, to see how well it performs.

Of course things rarely work perfectly the first time around, so at this point it’s pretty common for some refinement to be needed to increase accuracy. Luckily there are a number of tools to help do this without creating a new model from scratch, so it’s just a matter of tweaking until things perform acceptably.

Google Colab is free and the resulting CNNs are implemented in the TensorFlow Lite framework, meaning it’s possible to use them elsewhere. So if custom object detection has been holding up a project idea of yours, this might be what gets you over that hump.

High-Speed Sled Adds Bicycle Suspension

While you might have bought the best pair of skis in the 90s or 00s, as parts on boots and bindings start to fail and safety standards for ski equipment improve, even the highest-quality skis more than 15 or 20 years old will eventually become unsafe or otherwise obsolete. There are plenty of things that can be done with a pair of old skis, but if you already have a shot ski and an Adirondack chair made of old skis, you can put another pair to use building one of the fastest sleds we’ve ever seen.

[Josh Charles], the creator of this project, took inspiration from his father, who screwed an old pair of skis to the bottom of an traditional runner sled when he was a kid. This dramatically increased the speed of the sled, but eliminated its ability to steer. For this build [Josh] built a completely custom frame rather than re-use an existing sled, which allowed him to not only build a more effective steering mechanism for the skis, but also to use bicycle suspension components to give this sled better control at high speeds.

This build is part of a series that [Josh] did a few years ago, and you can find additional videos about it documenting his design process and his initial prototypes and testing. The amount of work he put into this build is evident when it’s seen finally traversing some roads that had been closed for winter; he easily gets the sled up in the 30 mph range several times. If you’re looking to go uphill in the snow, though, take a look at this powered snowboard instead.

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Make Your Own Pot And Encoder Knobs, Without Reinventing Them

Rotary potentiometers, switches, and encoders all share a basic design: adjustment is done via a shaft onto which a knob is attached, and knobs are sold separately. That doesn’t mean one knob fits all; there are actually a few different standards. But just because knobs are inexpensive and easily obtained doesn’t mean it’s not worth making your own.

A simple and effective indicator can be easily printed in a contrasting color.

Why bother 3D printing your own knobs instead of buying them? For one thing, making them means one can rest assured that every knob matches aesthetically. The ability to add custom or nonstandard markings are another bonus. Finally, there’s no need to re-invent the wheel, because [Tommy]’s guide to making your own knobs has it all figured out, with the OpenSCAD script to match.

By default, [Tommy]’s script will generate a knob with three shims (for interfacing to a splined shaft) when pot_knob(); is called. The number of shims can be adjusted by modifying potKnobDefaultShimCount. To give the knob a flat side (to interface with D-shafts), change flatted = false to flatted = true. And for adding a screw insert suitable for a set screw? Change tightenerDiameter = 0 from zero to the diameter desired.

The script is quite comprehensive and has sensible defaults, but it does require a bit of knowledge about OpenSCAD itself to use effectively. We have covered the basics of OpenSCAD in the past, and if you’re ready for a resource that will help you truly master it, here’s where to look.