Epoxy Fix For A Combusted PCB

September 26, 2018 by Dan Maloney 29 Comments

When the Magic Smoke is released, chances are pretty good that you’ve got some component-level diagnosis to do. It’s usually not that hard to find the faulty part, charred and crusty as it likely appears. In that case, some snips, a new non-crusty part, and a little solder are usually enough to get you back in business.

But what if the smoke came not from a component but from the PCB itself? [Happymacer] chanced upon this sorry situation in a power supply for an electric gate opener. Basking in the Australian sunshine for a few years, the opener started acting fussy at first, then not acting at all. Inspection of its innards revealed that some unlucky ants had shorted across line and neutral on the power supply board, which burned not only the traces but the FR4 of the board as well. Rather than replace the entire board, [Happymacer] carefully removed the carbonized (and therefore conductive) fiberglass and resin, leaving a gaping hole in the board. He fastened a patch for the hole from some epoxy glue; Araldite is the brand he used, but any two-part epoxy, like JB Weld, should work. One side of the hole was covered with tape and the epoxy was smeared into the hole, and after a week of curing and a little cleanup, it was ready for duty. The components were placed into freshly drilled holes, missing traces were replaced with wire, and it seems to be working fine.

This seems like a great tip to keep in mind for when catastrophe strikes your boards. There are more extreme ways to do it, of course, but perhaps none so flexible. After all, epoxy is versatile stuff.

Glorious Body Of Tracked ‘Mad Mech’ Started As Cardboard

March 11, 2018 by Donald Papp 10 Comments

[Dickel] always liked tracked vehicles. Taking inspiration from the ‘Peacemaker’ tracked vehicle in Mad Max: Fury Road, he replicated it as the Mad Mech. The vehicle is remote-controlled and the tank treads are partly from a VEX robotics tank tread kit. Control is via a DIY wireless controller using an Arduino and NRF24L01 modules. The vehicle itself uses an Arduino UNO with an L298N motor driver. Power is from three Li-Po cells.

The real artistic work is in the body. [Dickel] used a papercraft tool called Pepakura (non-free software, but this Blender plugin is an alternative free approach) for the design to make the body out of thin cardboard. The cardboard design was then modified to make it match the body of the Peacemaker as much as possible. It was coated in fiberglass for strength, then the rest of the work was done with body filler and sanding for a smooth finish. After a few more details and a good paint job, it was ready to roll.

There’s a lot of great effort that went into this build, and [Dickel] shows his work and process on his project page and in the videos embedded below. The first video shows the finished Mad Mech being taken for some test drives. The second is a montage showing key parts of the build process.

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Vacuum Molding With Kitchen Materials

December 26, 2017 by Brian McEvoy 14 Comments

Vacuum pumps are powerful tools because the atmospheric pressure on our planet’s surface is strong. That pressure is enough to crush evacuated vessels with impressive implosive force. At less extreme pressure differences, [hopsenrobsen] shows us how to cleverly use kitchen materials for vacuum molding fiberglass parts in a video can be seen after the break. The same technique will also work for carbon fiber molding.

We’ve seen these techniques used with commercially available vacuum bags and a wet/dry vac but in the video, we see how to make an ordinary trash bag into a container capable of forming a professional looking longboard battery cover. If the garbage bag isn’t enough of a hack, a ball of steel wool is used to keep the bag from interfering with the air hose. Some of us keep these common kitchen materials in the same cabinet so gathering them should ’t be a problem.

Epoxy should be mixed according to the directions and even though it wasn’t shown in the video, some epoxies necessitate a respirator. If you’re not sure, wear one. Lungs are important.

Fiberglass parts are not just functional, they can be beautiful. If plastic is your jam, vacuums form those parts as well. If you came simply for vacuums, how about MATLAB on a Roomba?

Thank you [Jim] who gave us this tip in the comments section about an electric longboard.

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Star Wars Speeder’s Finishing Touch: Mirrors

November 8, 2017 by Donald Papp 19 Comments

[Super 73] make electric scooters, and they made some Star Wars Speeder Bikes with a twist for Halloween; adding some mirrored panels around the bottoms of the bikes made for a decent visual effect that requires no upkeep or fancy workings. Having amazed everyone with the bikes, they followed them up with a video of the build process.

The speeders are shells built around their Super 73 electric scooter, with bases of what looks like MDF sitting on anchor points. Onto the base platforms goes cardboard and expanding foam to create the correct shapes, which are then sanded then coated in fiberglass and bondo. Then it’s time for paint, weathering, and all the assorted bits and pieces needed to make the speeders as screen-accurate as possible. The real finishing touch are the mirrored panels to conceal the wheels and create a levitation illusion. As long as the mirrors are angled so that they reflect the pavement when viewed by a pedestrian, it works fairly well.

Top it off with costumes and a ride around town (with plenty of cameras of course, they naturally wanted to grab some eyeballs) and we have to say, the end result looks nifty. Both the showcase and making-of videos are embedded below.

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How To Do Beautiful Enclosures With Custom Fiberglass

August 1, 2017 by Bil Herd 50 Comments

There are times when I feel the need to really make a mess. When I think of making messes with a degree of permanency, I think of fiberglass. I also really like the smell, reminds me of a simpler time in 8^th grade shop class. But the whole process, including the mess, is worth it for the amazing shapes you can produce for speaker pods and custom enclosures.

Utilizing fiberglass for something like a custom speaker pod for a car is not difficult, but it does tend to be tedious when it comes to the finishing stages. If you have ever done bodywork on a car you know what kind of mess and effort I am talking about. In the video below, I make a simple speaker pod meant for mounting a speaker to the surface of something like a car door.

You can also use a combination of wood and fiberglass to make subwoofer cabinets that are molded to the area around them. You can even replace your entire door panel with a slick custom shaped one with built in speakers if you’re feeling adventuresome.

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Hackaday Links: July 23, 2017

July 23, 2017 by Brian Benchoff 21 Comments

Hey, you know what’s happening right now? We’re wrapping up the third round of The Hackaday Prize. This challenge, Wheels, Wings, and Walkers, is dedicated to things that move. If it’s a robot, it qualifies, if it’s a plane, it qualifies, if it passes butter, it qualifies. There’s only a short time for you to get your entry in. Do it now. Superliminal advertising.

Speaking of the Hackaday Prize, this project would be a front-runner if only [Peter] would enter it in the competition. It’s one thing to have a cult; I have a cult and a petition to ‘stop’ me.

We were completely unaware of this project, but a few weeks ago, a cubesat was launched from Baikonur. This cubesat contains a gigantic mylar reflector, and once it’s deployed it will be the second brightest object in the night sky after the moon. I don’t know why we haven’t seen this in the press, but if you have any pictures of sightings, drop those in the comments.

In a mere two years, we’ll be looking at the 50th anniversary of the Apollo 11 landing. The mission control center at Johnson Space Center — where these landings were commanded and controlled — is still around, and it’s not in the best shape. There’s a Kickstarter to restore the Apollo Mission Control Center to its former glory. For the consoles, this means restoring them to Apollo 15 operational configuration.

We’ve seen 3D printed remote control airplanes, and at this point, there’s nothing really exceptional about printing a wing. This user on imgur is going a different direction with 3D printed fiberglass molds. Basically, it’s a fuselage for a Mustang that is printed, glued together, with the inside sanded and coated in wax. Two layers (3 oz and 6 oz) fiberglass is laid down with West Systems epoxy. After a few days, the mold is cracked open and a fuselage appears. This looks great, and further refinements of the process can include vapor smoothing of the inside of the mold, a few tabs to make sure the mold halves don’t break when the part is released, and larger parts in general.

The Darknet’s Casefile will take you to the limit of your existing knowledge. Join them, to go on a quest to improve your technical abilities.

This week is Def Con. That means two things. First, we’re on a hardware hunt. If you’ve been dedicating the last few months to #badgelife or other artisanal electronics, we want to hear about it. Second, [Joe Kim] made a graphic of the Tindie dog wearing a Hackaday hoodie and it’s adorable. There are a limited number of stickers of our hacker dog.

Gigabyte launched a single board computer with an Intel Apollo Lake CPU, discrete memory and storage, and a mini PCIe slot. Of course, this is being incorrectly marketed as a ‘Raspberry Pi competitor’, but whatever.

Soluble Molds For Composite Parts

March 13, 2017 by Brian Benchoff 16 Comments

People have been experimenting with 3D printed molds for fiberglass and carbon fiber for a while now, but these molds really aren’t much different from what you could produce with a normal CNC mill. 3D printing opens up a few more options for what you can build including parts that could never be made on any type of mill. The guys at E3D are experimenting with their new dissolvable filament to create incredible parts in carbon fiber.

For the last year, E3D has been playing around with their new soluble filament, Scaffold. This is the water-soluble support material we’ve all been waiting for: just throw it in a bucket of warm water and it disappears. The normal use case for this filament is as a support material, but for these experiments in composites, E3D are just printing whole objects, covering them in carbon fiber prepreg, vacuum bagging them, and allowing them to cure. Once the carbon fiber isn’t floppy and gooey, the support material is dissolved in water, leaving a perfect composite part.

E3D aren’t that experienced with composites, so they handed a bit of filament off to So3D for some additional experimentation. The most impressive part (in the title pic for this post) is a hollow twisted vase object. This would have required a six-part machined mold and would have cost thousands of dollars to fabricate. Additional experiments of embedding ABS parts inside the Scaffold mold were extremely successful.

As you would expect, there are limitations to this process. Since E3D are using a dissolvable mold, this is a one-time deal; you’re not going to be pulling multiple composite parts off a 3D printed mold like you would with a machined mold. Curing the parts in a very hot oven doesn’t work — Scaffold filament starts to sag around 60°C. Using prepreg is recommended over dry fabric and resin, but that seems to be due more to the skill of the person doing the layup rather than an issue with materials.