A mechanism made of brass and steel is attached to a milling machine. It has a long lever extending from the right side, a counterweight attached to the left side, and an indicator gauge in the middle.

A Precision Drill Press For Tiny Bits

May 16, 2026 by Aaron Beckendorf 11 Comments

Anyone who’s worked with even a 1 mm bit knows that while a drill press is all but essential, it isn’t proof against broken bits. Working with a 0.1 mm drill bit seems, therefore, all but impossible, which is why [Mike] of Chronova Engineering built this mechanism to simplify such drilling.

The mechanism is an attachment for a milling machine, and in principle it just needs to move the rotating drill bit up and down. It needs to be extremely precise, though. For context, a good-quality chuck normally has a runout of 30 to 50 microns, which is approaching half the diameter of the drill bit. The mechanism has a collet mounted in the milling machine’s spindle, which transfers rotation to a second spindle. The second spindle is mounted to a runout-compensating drill chuck, and is connected to a lever and counterweight which allow the user to make small, low-force movements. A dial indicator lets the user see how far the bit’s descended.

Most of the parts were machined out of steel or brass, with the handle being made of titanium for lower weight. When the finished device was mounted to the milling machine, the measured runout was severe. After much investigation and reworking, however, the problem turned out to be a damaged collet locating pin, not an issue with the drilling mechanism. As a first test, [Mike] drilled a 0.1 mm hole 1.8 mm deep, then as a challenge drilled six 0.1 mm holes in the end of a thin steel wire. The results weren’t quite as uniform as he wanted, but it took a scanning electron microscope to even see the imperfection.

It won’t help much with very fine drill bits, but if you need a very precisely-placed hole, check out this periscopic drilling camera. If you do break a drill bit in the workpiece, you might be able to dissolve it with alum.

Continue reading “A Precision Drill Press For Tiny Bits” →

How To Make A 13 Mm Hole With A 1/2″ Drill Bit

March 29, 2025 by Donald Papp 75 Comments

As everyone knows, no matter how many drill bits one owns, one inevitably needs a size that isn’t on hand. Well, if you ever find yourself needing to drill a hole that’s precisely 13 mm, here’s a trick from [AvE] to keep in mind for doing it with a 1/2″ bit. It’s a hack that only works in certain circumstances, but hey, it just may come in handy some day.

So the first step in making a 13 mm hole is to drill a hole with a 1/2″ bit. That’s easy enough. Once that’s done, fold a few layers of tinfoil over into a small square and lay it over the hole. Then put the drill bit onto the foil, denting it into the hole (but not puncturing it) with the tip, and drill at a slow speed until the foil wraps itself around the bit like a sheath and works itself into the hole. The foil enlarges the drill bit slightly and — as long as the material being drilled cooperates — resizes the hole a tiny bit bigger in the process. The basic idea can work with just about any drill bit.

It’s much easier demonstrated than described, so watch it in action in the video around the 2:40 mark which will make it all very clear.

It’s not the most elegant nor the most accurate method (the hole in the video actually ends up closer to 13.4 mm) but it’s still something worth keeping in the mental toolbox. Just file it away along with laying your 3D printer on its side to deal with tricky overhangs.

Continue reading “How To Make A 13 Mm Hole With A 1/2″ Drill Bit” →

A dismantled drill on a cluttered workbench

Going Brushless: Salvaging A Dead Drill

January 29, 2025 by Heidi Ulrich 26 Comments

Let’s face it—seeing a good tool go to waste is heartbreaking. So when his cordless drill’s motor gave up after some unfortunate exposure to the elements, [Chaz] wasn’t about to bin it. Instead, he embarked on a brave journey to breathe new life into the machine by swapping its dying brushed motor for a sleek brushless upgrade.

Things got real as [Chaz] dismantled the drill, comparing its guts to a salvaged portable bandsaw motor. What looked like an easy swap soon became a true hacker’s challenge: incompatible gear systems, dodgy windings, and warped laminations. Not discouraged by that, he dreamed up a hybrid solution: 3D-printing a custom adapter to make the brushless motor fit snugly into the existing housing.

The trickiest part was designing a speed control mechanism for the brushless motor—an impressively solved puzzle. After some serious elbow grease and ingenuity, the franken-drill emerged better than ever. We’ve seen some brushless hacks before, and this is worth adding to the list. A great tool hack and successful way to save an old beloved drill. Go ahead and check out the video below!

Continue reading “Going Brushless: Salvaging A Dead Drill” →

Drilling Rig Makes Accurate Holes In Seconds

November 23, 2024 by Zoe Skyforest 19 Comments

Drilling holes can be quite time consuming work, particularly if you have to drill a lot of them. Think about all the hassle of grabbing a part, fixturing it in the drill press, lining it up, double checking, and then finally making the hole. That takes some time, and that’s no good if you’ve got lots of parts to drill. There’s an easy way around that, though. Build yourself a rad jig like [izzy swan] did.

The first jig we get to see is simple. It has a wooden platter, which hosts a fixture for a plastic enclosure to slot perfectly into place. Also on the platter is a regular old power drill. The platter also has a crank handle which, when pulled, pivots the platter, runs the power drill, and forces it through the enclosure in the exact right spot. It’s makes drilling a hole in the enclosure a repeatable operation that takes just a couple of seconds. The jig gets it right every time.

The video gets better from there, though. We get to see even niftier jigs that feature multiple drills, all doing their thing in concert with just one pull of a lever. [izzy] then shows us how these jigs are built from the ground up. It’s compelling stuff.

If you’re doing any sort of DIY manufacturing in real numbers, you’ve probably had to drill a lot of holes before. Jig making skills could really help you if that’s the case. Video after the break.

Continue reading “Drilling Rig Makes Accurate Holes In Seconds” →

Change The Jingle In Your Makita Charger Because You Can

February 16, 2024 by Zoe Skyforest 20 Comments

Lots of things beep these days. Washing machines, microwaves, fridge — even drill battery chargers. If you’re on Team Makita, it turns out you can actually change the melody of your charger’s beep, thanks to a project from [Real-Time-Kodi].

The hack is for the Makita DR18RC charger, and the implementation of the hack is kind of amusing. [Real-Time-Kodi] starts by cutting the trace to the buzzer inside the charger. Then, an Arduino is installed inside the charger, hooked up to the buzzer itself and the original line that was controlling it. When it detects the charger trying to activate the buzzer, it uses this as a trigger to play its own melody on the charger instead. The Arduino also monitors the LEDs on the charger in order to determine the current charge state, and play the appropriate jingle for the situation.

It’s an amusing hack, and one that could certainly confuse the heck out of anyone expecting the regular tones out of their Makita charger. It also shows that the simple ways work, too — there was no need to dump any firmware or decompile any code.

Continue reading “Change The Jingle In Your Makita Charger Because You Can” →

Force Feedback Steering Wheel Made From Power Drill

August 3, 2023 by Bryan Cockfield 22 Comments

When it comes to controllers for racing games, there is perhaps no better option than a force feedback steering wheel. With a built-in motor to push against the wheel at exactly the right times, they can realistically mimic the behavior of a steering wheel from a real car. The only major downside is cost, with controllers often reaching many hundreds of dollars. [Jason] thought it shouldn’t be that hard to build one from a few spare parts though and went about building this prototype force feedback steering wheel for himself.

Sourcing the motor for the steering wheel wasn’t as straightforward as he thought originally. The first place he looked was an old printer, but the DC motor he scavenged from it didn’t have enough torque to make the controller behave realistically, so he turned to a high-torque motor from a battery-powered impact driver. This also has the benefit of coming along with a planetary gearbox as well, keeping the size down, as well as including its own high-current circuitry. The printer turned out to not be a total loss either, as the encoder from the printer was used to send position data about the steering wheel back to the racing game. Controlling the device is an Arduino, which performs double duty sending controller information from the steering wheel as well as receiving force feedback instructions from the game to drive the motor in the steering wheel. Continue reading “Force Feedback Steering Wheel Made From Power Drill” →

Angled Drill Guide Helps You With Those Tricky Holes

August 18, 2022 by Zoe Skyforest 18 Comments

If you’ve ever tried to drill a hole on an angle with a power drill, you’ve probably drilled some pretty shocking holes. To do it right, you really need some mechanical assistance, and this jig from [Kartik_Nandrui] should do the trick.

The device uses a guide that sits on the surface to be drilled, with a pair of angled connectors that fit two wooden dowels. These connect the guide to a corresponding sleeve that fits around the drill body. The sleeve then slides up and down the dowels, allowing the drill to move in a straight line towards the targeted area.

It’s a useful hack, but we can see room for some improvements that would take it to the next level. Having a way to lock the angle of the guide base would be great for accuracy. As it’s 3D printed, it would also be simple to create a version with a curved guide base that could fit over pipes, or other designs to fit complex geometries like roof sheeting or other corrugated materials.

Sometimes the most interesting hacks are the ones that get us thinking about our own potential projects. If you’ve got any creative tool hacks you’ve been brewing up in the lab, be sure to let us know!