Supercon 2022: Sam Mulvey Shows You How To FM Radio

December 15, 2022 by Elliot Williams 19 Comments

Sam Mulvey built his own radio station in Tacoma, WA. Is there a better way to meld ham radio practice with a colossal number of DIY electrical and computer projects? Sam would say there isn’t one! This 45-minute talk is basically the lessons-learned review of setting up KTQA 95.3 – the radio station on the hill.

Sam starts out the talk by introducing you to LPFM. And maybe you didn’t know that there’s a special type of license issued by the US FCC allowing non-profit community radio stations up to 100 W, covering an radius of around 5 km. It’s like running a pirate radio station, but by jumping through a few legal hoops, made legal.

Trash on the Radio

Putting a radio station together on a budget requires a ton of clever choices, flexibility, and above all, luck. But if you’re willing to repair a busted CD player or turntable, scrounge up some used computers, and work on your own amplifiers, the budget doesn’t have to be the limiting factor.

Being cheap means a lot of DIY. For instance, Sam and friends made a custom console to support all the gear and hide all the wiring. Some hot tips from the physical build-out: painted cinderblocks make great studio monitor stands, and Cat-5 can carry two channels of balanced audio along with power, with sufficient isolation that it all sounds clean. Continue reading “Supercon 2022: Sam Mulvey Shows You How To FM Radio” →

DIY Heat-Set Insert Press Says Complicated = Comfort

October 23, 2022 by Donald Papp 17 Comments

Heat-set inserts are a great way to embed mechanically-strong, threaded parts into a 3D print. For installation, all that is required is an economical soldering iron; something most of us already have.

The carriage and counterweight use a v-wheel gantry, GT2 belt, and other common hardware.

That’s fine for a handful of occasional inserts, but when a large number need to be inserted reliably and cleanly, something a little more refined is called for. That’s where [virchow]’s threaded insert press design comes in. It adds 3D-printed parts to an aluminum extrusion frame to create a press that smoothly lowers a soldering iron directly up and down, with minimal effort by the user.

The holder for the soldering iron is mounted to a small v-wheel gantry that rides along the vertical extrusion. The gantry features a counterweight to take care of resetting the position of the iron. [Virchow] admits that the design could be considered unnecessarily complicated (hence the “UC” in the name) but on the other hand, there’s nothing like doing a hundred or so inserts to make one appreciate every bit of comfort and stability.

Heat-set inserts aren’t difficult to use, but a little technique goes a long way. Spend a few minutes reading Joshua Vasquez’s guide on the optimal way to use them in 3D-printed parts to make sure yours not only go in straight but end up looking great as well.

3D Printed Sorter Separates Spare Hex Nuts With A Shake

October 13, 2022 by Donald Papp 14 Comments

Got a pile of mixed hex nuts? Sort them in no time by printing [jonafriendj]’s nut sorter, which has options for pretty much any nut size you’d be after (it’s labeled metric, but actually includes Imperial sizes as well.)

Something to admire about the design is the handy little raised labels on each of the sieves, and the fact that all the parts print entirely without supports. Designing a part to play to a manufacturing method’s strengths (and avoid its weaknesses) is good DFM, or Design for Manufacturing.

With 3D printing being the boon that it is to workshops and hobbyists everywhere, it certainly pays to strive for good DFM, especially for designs meant to be shared with others. Sometimes good DFM takes a page from other manufacturing methods like injection molding, and we end up with things like using crush ribs on printed parts.

Want to see a demonstration of [jonafriendj]’s nut sorting design? Check out the short video embedded below the page break. If that leaves you wanting, take a look at a motorized, automated DIY solution.

Continue reading “3D Printed Sorter Separates Spare Hex Nuts With A Shake” →

DIy Arduino FM radio enclosure with the lid off, showing the electronics inside

DIY Arduino Due TEA5767 FM Radio

October 8, 2022 by Dave Walker 10 Comments

Older hackers will remember that a crystal set radio receiver was often one of the first projects attempted. Times have changed, but there’s still something magical about gathering invisible signals from the air and listening to the radio on a homemade receiver. [mircemk] has brought the idea right up to date by building an FM radio with an OLED display, controlled with a rotary encoder.

The design is fairly straightforward, based as it is on another project that [mircemk] found on another site, but the build looks very slick and would take pride of place on any hacker’s workbench. An Arduino Due forms the heart of the project, controlling a TEA5767 module, an SH1106 128×64 pixel OLED display and a rotary encoder. The sound signal is passed through an LM4811 headphone amplifier for private listening, and a PAM8403 Class D audio amplifier for the built-in loudspeaker. The enclosure is made from PVC panels, and accented with colored adhesive tape for style.

It’s easier than ever before to quickly put together projects like this by connecting pre-built modules and downloading code from the Internet, but that doesn’t mean it’s not a worthwhile way to improve your skills and make some useful devices like this one. There are so many resources available to us these days and standing on the shoulders of giants has always been a great way to see farther.

We’ve shown some other radio projects using Arduinos and the TEA5767 IC in the past, such as this one on a tidy custom PCB, and this one built into an old radio case.

Continue reading “DIY Arduino Due TEA5767 FM Radio” →

The Filamentmeter: For When You Absolutely Want To Count Every Meter Used

September 9, 2022 by Donald Papp 17 Comments

[ArduinoNmore] took an interesting approach to designing a counter intended to accurately display how many meters of filament a 3D printer has used. The Filamentmeter looks a little bit like a 3D printed handheld tally counter (or lap counter) but instead of a button to advance each digit, the readout represents how many meters of filament have gone through the extruder.

Driving the digit rotation from the extruder motor itself means that even retractions are accounted for.

At first glance it may look like there is a motor hidden inside, or that the device is somehow sensing the filament directly. But it’s actually the movement of the extruder motor that drives the device. A small spur gear attached to the printer’s extruder drives a series of gears that advance the digits. This means that retractions — small reverses of the extruder motor during printing — are properly accounted for in the total, which is a nice touch.

[ArduinoNmore] designed this for the Ender 3, and the Filamentmeter relies on a specific extruder design and orientation to work properly. Of course, since it’s 3D printed, modifying the design for your own purposes should be pretty straightforward.

Curious? The design is being sold for a few bucks, and there is a free test piece one can print and use to confirm whether the design will work before mashing the buy button. Non-free printable 3D models can be a world of buyer beware, but test pieces and solid documentation are good ways to give buyers confidence in your work.

The insides of the unit are really quite intricate, with a clockwork-type elegance to them. You can see it all in the short video, embedded below.

Continue reading “The Filamentmeter: For When You Absolutely Want To Count Every Meter Used” →

Touch Tone MIDI Phone And Vocoder Covers Daft Punk

September 6, 2022 by Donald Papp 3 Comments

[poprhythm]’s Touch Tone MIDI Phone is a fantastic conversion of an old touch tone phone into a MIDI instrument complete with intact microphone, but this project isn’t just about showing off the result. [poprhythm] details everything about how he interfaced to the keypad, how he used that with an Arduino to create a working MIDI interface, and exactly how he decided — musically speaking — what each button should do. The LEDs on the phone are even repurposed to blink happily depending on what is going on, which is a nice touch.

Of course, it doesn’t end there. [poprhythm] also makes use of the microphone in the phone’s handset. Since the phone is now a MIDI instrument with both a microphone and note inputs, it’s possible to use them together as the inputs to vocoder software, which he demonstrates by covering Around the World by Daft Punk (video).

We love how [poprhythm] explains how he interfaced to everything because hardware work is all about such details, and finding the right resources. Here’s the GitHub repository for the Arduino code and a few links to other resources.

We have seen MIDI phone projects before, and each one is always unique in its own way: here’s a different approach to converting a keypad phone to MIDI, and this rotary pulse-dial phone went in a completely different direction with the phone itself completely unmodified, using only external interfacing.

You can admire [poprhythm]’s Touch Tone MIDI Phone in action in the short videos embedded below, with each one showing off a different aspect of the build. It’s great work!

Continue reading “Touch Tone MIDI Phone And Vocoder Covers Daft Punk” →

DIY LED Bulb Lacks Correct Lugs, So M3 Bolts To The Rescue

August 15, 2022 by Donald Papp 30 Comments

[Damo] has an interesting LED bulb project with a neat twist: he converted some outdoor lighting to 12 V LED lighting with some self-designed bulb replacements and decided to reuse the existing GU10 sockets and wiring. That meant putting GU10 lugs onto his custom PCBs, but he ran into a snag.

These GU10 bulb lugs are tough to buy in small quantities. Luckily, M3 socket head bolts are a near-perfect match.

Those distinctive lugs that twist into GU10 sockets? [Damo] simply couldn’t find anywhere offering to sell them in small quantities. So he did what any enterprising hacker would do and found a substitute that was both accessible and economical: M3 bolts. Apparently, socket-headed M3 bolts are pretty much identical in size to GU10 lugs. Who’d have thought?

[Damo]’s retrofit worked great, and thanks to M3 bolts he was able to re-use the existing weatherproof wiring and sockets in his yard. His design files are here on GitHub.

We do love using things for other than their intended purpose, but as [Damo] points out, GU10 sockets are normally connected to mains power. So if you decide to use his design (or use GU10 sockets for your own purposes), be aware that you’ll have hardware that looks interchangeable with other (mains-connected) sockets, but isn’t. Be mindful of that, and take appropriate precautions. Avoiding electrical oopsies is always worth putting effort into, after all.