Grease Gun Hydroforms Custom Motorcycle Parts

Never underestimate the power of an incompressible fluid at high pressure. Properly constrained and with a full understanding of the forces involved, hydraulic pressure can be harnessed to do some interesting things in the home shop, like hydroforming stainless steel into custom motorcycle parts.

From the look of [Clarence Elias]’s video below, it seems like he has a 100% custom motorcycle build going on in his shop. That means making every part, including the reflectors for the lights. While he certainly could have used a traditional approach, like beating sheet stainless with a planishing hammer or subjecting it to the dreaded English wheel, [Clarence] built a simple yet sturdy hydroforming die for the job. A thick steel ring clamps the sheet stainless to a basal platen with an inlet from the forming fluid, which is ordinary grease. [Clarence] goes through the math and the numbers are impressive — a 1,500-psi grease gun can be mighty persuasive under such circumstances. The result is a perfectly formed dish with no tool marks, in need of only a little polishing to be put into service.

Whether by a pressure washer, a puff of air, or 20-tons of pressure on a rubber pad, hydroforming is a great method to master for making custom parts.

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Low-Budget Hydroformer Puts the Squeeze on Sheet Metal Parts

Between manufacturing technologies like 3D-printing, CNC routers, lost-whatever metal casting, and laser and plasma cutters, professional quality parts are making their way into even the most modest of DIY projects. But stamping has largely eluded the home-gamer, what with the need for an enormous hydraulic press and massive machined dies. There’s more than one way to stamp parts, though, and the budget-conscious shop might want to check out this low-end hydroforming method for turning sheet metal into quality parts.

If hydroforming sounds familiar, it might be because we covered [Colin Furze]’s attempt, which used a cheap pressure washer to inflate sheet metal bubbles with high-pressure water. The video below shows a hydroformer that [Rainbow Aviation] uses (with considerably less screaming) to make stamped aluminum parts for home-brew aircraft. The kicker with this build is that there is no fluid — at least not until the 40,000-pound hydraulic press semi-liquifies the thick neoprene rubber pad placed over the sheet metal blank and die. The pressure squeezes the metal into and around the die, forming some pretty complex shapes in a single operation. We especially like the pro-tip of using Corian solid-surface countertop material offcuts to make the dies, since they’re available for a pittance from cabinet fabricators.

It’s always a treat to see hacks from the home-brew aviation world. They always seem to have plenty of tricks and tips to share, like this pressure-formed light cowling we saw a while back.

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Get Down to the Die Level with this Internal Chip Repair

Usually, repairing a device entails replacing a defective IC with a new one. But if you’ve got young eyes and haven’t had caffeine in a week, you can also repair a defective chip package rather than replace it.

There’s no description of the incident that resulted in the pins of the QFP chip being ablated, but it looks like a physical insult like a tool dropped on the pins. [rasminoj]’s repair consisted of carefully grinding away the epoxy cap to expose the internal traces leading away from the die and soldering a flexible cable with the same pitch between the die and the PCB pads.

This isn’t just about [rasminoj]’s next-level soldering skills, although we’ll admit you’ve got to be pretty handy with a Hakko to get the results shown here. What we’re impressed with is the wherewithal to attempt a repair that requires digging into the chip casing in the first place. Most service techs would order a new board, or at best solder in a new chip. But given that the chip sports a Fanuc logo, our bet is that it’s a custom chip that would be unreasonably expensive to replace, if it’s even still in production. Where there’s a skill, there’s a way.

Need more die-level repairs? Check out this iPhone CPU repair, or this repair on a laser-decapped chip.

[via r/electronics]

Giant D20 Is A Critical Hit in More Ways than One

[Mikael Vejdemo-Johansson] is a member of the NYC Resistor hackerspace and an avid fan of a D&D themed improv theatre called The Campaign. To show his appreciation, he decided to gift them a Christmas present: a giant D20. The original plan called for integrated LEDs to burst alight on a critical hit or miss, or let out pulses if it landed on another face. Cool, right? Well, easier said than done.

[Vejdemo-Johansson] figured a circle of 4 tilt sensors mounted on the one and twenty face would be enough to detect critical rolls. If any of the switches were tilted beyond 30 degrees, the switch would close. He mounted eight ball-tilt switches and glued in the LEDs. A hackerspace friend also helped him put together an astable multivibrator to generate the pulses for non-critical rolls.

This… did not work out so well. His tilt sensor array proved to be a veritable electronic cacophony and terribly sensitive to any movement. That and some other electronic troubles forced a shelving of any light shows on a critical hit or miss. [Vejdemo-Johansson] kept the pulsing LEDs which made for a cool effect when shining through the mirrored, red acrylic panes he used for the die faces. Foam caulk backer rods protect as the die’s structure to stop it from being shattered on its first use.

Before The Campaign’s next show, [Vejdemo-Johansson] managed to stealthily swap-out of the troupe’s original die with his gift, only for it to be immediately thrown in a way that would definitely void any electronic warranty. Check out the reveal after the break (warning, some NSFW language)!

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Simple Shop-made Taps for Threading Wood

Wood can be the material of choice for many kinds of projects, but it often falls out of the running in favor of metal or plastic if it needs to take a threaded fastener. But with a little ingenuity you can make your own wood taps and cut threads that will perform great.

Making wood do things that wood isn’t supposed to do is [Matthias Wandel]’s thing. Hackers the world over know and use his wood gears designer to lay out gears for all kinds of projects from musical marble machines to a wooden Antikythera mechanism. Woodworkers have been threading wood for centuries , so making wood take a decent thread isn’t exactly something new. But doing it on the cheap and making the threads clean and solid has always been tricky. The video after the break shows [Matthias]’ method of cutting a tap out of an ordinary threaded rod or even off-the-shelf lag screws. He uses a simple jig to hold the blank so that flutes can be cut with an angle grinder. The taps work well in the materials he tested, and a little informal stress testing at the end of the video shows promise for long service life of the threads.

Wood threads aren’t suitable for every project, but knowing that you can do it might just open the path to a quick, easy build. This is a great tip to keep in mind.

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Closer Look at Everyone’s Favorite Blinky

Admit it, you love looking at silicon die shots, especially when you have help walking through the functionality of all the different sections. This one’s really easy for a couple of reasons. [electronupdate] pointed his microscope at the die on a WS2812.

The WS2812 is an addressible RGB LED that is often called a Neopixel (a brand name assigned to it by Adafruit). The part is packaged in a 5×5 mm housing with a clear window on the front. This lets you easily see the diodes as they are illuminated, but also makes it easy to get a look at the die for the logic circuit controlling the part.

This die is responsible for reading data as it is shifted in, shifting it out to the next LED in the chain, and setting each of the three diodes accordingly. The funcitonality is simple which makes it a lot easier to figure out what each part of the die contributes to the effort. The diode drivers are a dead giveaway because a bonding wire connected to part of their footprint. It’s quite interesting to hear that the fourth footprint was likely used in testing — sound off in the comments if you can speculate on what those tests included.

We had no trouble spotting logic circuitry. This exploration doesn’t drill down to the gate level like a lot of [Ken Shirriff’s] silicon reverse engineering but the process that [electronupdate] uses is equally fun. He grabs a tiny solar cell and scopes it while the diodes are running to pick up on the PWM pattern used to fade each LED. That’s a neat little trick to keep in your back pocket for use in confirming your theories about clock rate and implementation when reverse engineering someone else’s work.

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Yes, You Can Reverse Engineer this 74181

[Ken Shirriff] is the gift that keeps on giving this new year. His latest is a reverse engineering of the 74181 Arithmetic Logic Unit (ALU). The great news is that the die image and complexity are both optimized for you to succeed at doing your own reverse engineering.

74181-openedWe have most recently seen [Ken] at work explaining his decapping and reverse engineering process at the Hackaday SuperCon followed soon after by his work on the 8008. That chip is crazy with complexity and a die-ogling noob (like several of us on the Hackaday crew) stands no chance of doing more than simply following along with what he explains. This time around, the 74181 is just right for the curious but not obsessed. Don’t believe me? The 8008 had around 3,500 transistors while the friendly 74181 hosts just 170. We like those odds!

A quick crash course in visually recognizing transistors will have you off to the races. [Ken] also provides reference for more complex devices. But where he really saves the day is in his schematic analysis. See, the traditional ‘textbook’ logic designs have been made faster in this chip and going through his explanation will get you back on track to follow the method behind the die’s madness.

[Ken] took his own photograph of the die. You can see the donor chip above which had its ceramic enclosure shattered with a brisk tap from a sharp chisel.