Simple Machining Process Repairs Broken Control Knob

[Francisco] is helping his mother with a repair to the headlight knob on her Ford Ranger. Above you can see the broken knob on the left, and what it is supposed to look like on the right (taken from [Francisco’s] own vehicle for reference). We’ve encountered split shafts on plastic knobs before and decided it was not something that could be fixed. But he didn’t give up so easily. He mentions that you can purchase a replacement for a few bucks, but he has the means to repair the knob by machining a metal bushing.

The idea is that you mill a metal ring whose inner diameter matches what the outer diameter of the plastic shaft should be. By inserting the broken knob in the ring, the plastic is held tightly together as if it had never broken. In the video after the break [Francisco] uses a metal pencil body from his junk box and a mini-lathe to cut the bushing to length, and mill the inner diameter to his specifications.

He talks about the difficulty of getting replacement parts in Chile, where he lives. But we think this kind of thrift is a great example for all hackers. If you’ve got the tools why not use them? And if you don’t have them, here’s a great excuse to procure them!

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Arduino Based EATC Replacement

The Electronic Automatic Temperature Control Module on [Dan Mattox’s] 2000 Ford Taurus bit the dust. The junkyards in the area didn’t have a matching replacement and a new one is pretty hard to come by so he built an EATC  replacement from an Arduino Mega. It includes a solenoid controller board for the vent selector, blower control, and new switches to control the power windows. He’s got the system up and running which is important because after removing the broken EATC the car was stuck blowing 90-degree air at full blast. He’s put together a demo and an installation video which we’ve embedded after the break but there’s also a photo album you can page through. The sketch that we developed to control the system is up at pastebin so get it while it’s hot.

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