Four times the holes, four times the trouble. With the fate of repetitive motion injury looming due to the need to drill 1,200 holes, [bitluni] took matters into his own hands and built this nifty DIY hole punch for light-gauge sheet metal.
A little backstory will probably help understand why [bitluni] needs so many holes. Back in May, he built a ping pong ball LED video wall for Maker Faire Berlin. That had 300 LEDs and came out great, but at the cost of manually drilling 300 holes in sheet steel with a hand drill. Looking to expand his wall of balls to four times the original size, [bitluni] chose to spend a few days building a punch to make the job more appealing. The business end, with solid bar stock nested inside pieces of tubing, is a great example of how much you can get done without a lathe. The tool is quite complex, with a spring-loaded pilot to help guide the punching operation. When that proved impractical, [bitluni] changed the tool design and added an internal LED to project crosshairs from inside the tool.
The tool itself is mounted into a sturdy welded steel frame that allows him to cover the whole aluminum sheet that will form the panel of his LED wall. It’s pretty impressive metalwork, especially considering this isn’t exactly in his wheelhouse. And best of all, it works – nice, clean holes with no deformation, and it’s fast, too. We’re looking forward to seeing the mega-LED wall when it’s done.
Continue reading “Punch Those Hole-Drilling Blues Away With A Homebrew Punching Tool”
Drilling holes is easy; humans have been doing it in one form or another for almost 40,000 years. Drilling really tiny holes in hard materials is more challenging, but still doable. Drilling deep, straight holes in hard materials is another thing altogether.
Luckily, these days we have electric discharge machining (EDM), a technique that opens up all kinds of possibilities. And just as luckily, [Ben Krasnow] got his hands on some EDM gear to try out, with fascinating results. As [Ben] explains, at its heart EDM is just the use of a small arc to ablate metal from a surface. The arc is precisely controlled, both its frequency via an arc controller, and its location using CNC motion control. The arc controller has always been the sticking point for home EDM, but the one [Ben] tried out, a BaxEDM BX17, is squarely aimed at the small shop market. The whole test platform that [Ben] built has a decidedly home-brew look to it, with a CNC gantry rigged up to a water tank, an EDM drill head spinning the drill rods slowly, and an airless paint gun providing high-pressure process fluid. The video below shows that it works remarkably well nonetheless.
While we’re certainly keen to see [Ben]’s promised videos on EDM milling and cutting, we doubt we’ll line up to shell out €2,950 for the arc controller he used. If you have more courage than money, this mains-powered EDM might be a better fit.
Continue reading “[Ben Krasnow] Drills Really Small Holes With Electricity”
If you’re cutting metal in the workshop, you’re likely using a table-mounted cutoff saw, or perhaps a bandsaw for finer work. The power hacksaw is an unwieldy contraption that looks and feels very old fashioned in its operation. Despite the drawbacks inherent in the design, [Emiel] decided to build one that operates under drill power, and it came out a treat.
The build uses a basic battery powered drill as its power source. This is connected to a shaft which rotates a linkage not dissimilar to that seen on steam locomotives, but in reverse. The linkage in this case is turning the rotational motion of the drill into linear motion of the hacksaw, which moves along a metal rail, guided by a 3D printed bearing.
With a body of plywood and plastic moving parts, this might not be your tool of choice for high-volume, fast paced work. However, as [Emiel] notes, it’s faster than doing it by hand, and it was a fun build that by and large, used what was already lying around the workshop. It’s not the first time we’ve seen a powered hacksaw use 3D printed parts, either. Video after the break.
Continue reading “This Home Made Power Hacksaw Cuts Quick And Clean”
Low-slung body style. Four-wheel drive. All electric drivetrain. Turns on a dime. Neck-snapping acceleration. Leather seating surface. Is it the latest offering from Tesla? Nope; it’s a drill-powered electric utility vehicle, and it looks like a blast to drive.
Surprisingly, this isn’t a just-for-kicks kind of build. There’s actually a practical reason for the low form factor and long range of [Axel Borg]’s little vehicle. We’ll leave the back story to the second video below, but suffice it to say that this will be a smaller version of the crawler NASA used to roll rockets out to the launch pad, used instead to transport his insanely dangerous looking manned-multicopter. The running gear on this vehicle is the interesting bit: four hefty electric drills, one for each of the mobility cart wheels. The drills are powered by a large series-connected battery pack putting out 260V at full charge. The universal motors of the drills are fine with DC, and the speed of each is controlled via the PWM signals from a pair of cordless drills. The first video below shows [Axel] putting it through its paces; he didn’t hold back at all, but the vehicle kept coming back for more.
We know this cart is in service to another project, but we’d have a hard time concentrating on anything if we had the potential for that much fun sitting in the shop. Still, we hope that multirotor gets a good test flight soon, and that all goes well with it.
Continue reading “A Quartet Of Drills Put The Spurs To This Electric Utility Vehicle”
If necessity is the mother of invention, then laziness is probably its father. Or at least a close uncle. Who hasn’t thought, “There has to be a better way to do this, one that doesn’t involve me burning precious calories”?
Motivational laziness seems to increase with potential energy, as anyone who needs to haul groceries up four flights of stairs will tell you. This appears to be where this balcony-mounted drill-powered crane came from. Starting with a surplus right-angle gearbox and drum, [geniusz K] fabricated the rest of the crane from steel plate and tubing. We like the quality of fabrication and the tip on making slip couplings from bits of square tubing. The finished product got a nice coat of brown paint to match the balcony railing; keeping the neighbors happy is always important. He tested the crane with a 20-kg weight before installing it on the balcony and put it to work hauling groceries up three stories. Check out the build and the test in the video below.
While it won’t set any speed records, at least the drill is doing the work. But what if you’re impatient as well as lazy? Aside from being two-thirds of the way to programming greatness, you may have to up the game. A heavy-lift quadcopter, perhaps?
Continue reading “A DIY Balcony Crane Lifts Groceries For The Lazy But Patient”
Never underestimate the importance of fixturing when you’re machining parts. No matter what the material, firmly locking it down is the key to good results, and may be the difference between a pleasant afternoon in the shop and a day in the Emergency Room. Flying parts and shattered tooling are no joke, but a lot of times quality commercial solutions are expensive and, well, commercial. So this scratch-built drill press vise is something the thrifty metalworker may want to consider.
To be sure, [Ollari’s] vise, made as it is almost completely from scrap angle iron, is no substitute for a vise made from precision ground castings. But it’s clear that he has taken great care to keep everything as square and true as possible, and we give him full marks for maximizing his materials. And his tools — nothing more complicated than a MIG welder is used, and most of the fabrication is accomplished with simple hand tools. We like the way he built up sturdy profiles by welding strap stock across the legs of the angle iron used for the jaws, to give them a strong triangular cross-section to handle the clamping force. And using the knurled end of an old socket wrench as the handle was inspired; we’ll certainly be filing that idea away for a rainy day in the shop. Although we might use Acme rather than plain threaded rod.
We always enjoy seeing someone fabricate their own tools, and this one reminds us a bit of the full-size bench vise built up from layers of welded steel we featured a while back. It even looks a little like this 3D-printed vise, too.
Continue reading “A Scratch-Built Drill Press Vise From Scrap”
We have a lot of respect for the hackers at NASA’s Jet Propulsion Laboratory (JPL). When their stuff has a problem, it is often millions of miles away and yet they often find a way to fix it anyway. Case in point is the Curiosity Mars rover. Back in 2016, the probe’s rock drill broke. This is critical because one of the main things the rover does is drill into rock samples, collect the powder and subject it to analysis. JPL announced they had devised a way to successfully drill again.
The drill failed after fifteen uses. It uses two stabilizers to steady itself against the target rock. A failed motor prevents the drill bit from retracting and extending between the stabilizers. Of course, sending a repair tech 60 million miles is not in the budget, so they had to find another way. You can see a video about the way they found, below.
Continue reading “NASA Remotely Hacks Curiosity’s Rock Drill”