Becoming accomplished with a lathe is a powerful skillset, but it’s only half of the journey. Being clever comes later, and it’s the second part of the course. Patience is in there somewhere too, but let’s focus on being clever. [TimNummy] wants a knobbed bolt with critical parameters, so he makes his own. After the break, there is a sixty-second summary of the linked video.
Making stock hardware is a beginner’s tasks, so custom hardware requires ingenuity or expensive machinery. Adding finger notches to a bolthead is arbitrary with an indexing chuck, but one isn’t available. Instead, hex stock becomes a jig, and the flat sides are utilized to hold the workpiece at six intermittent angles. We can’t argue with the results which look like a part that would cost a pretty penny.
Using material found in the workshop is what being clever is all about. Hex brass stock comes with tight tolerances on the sides and angles so why not take advantage of that?
[TimNummy] can be seen on HaD for his Jeep dome light hack and an over-engineered mailbox flag. Did you miss [Quinn Dunki]’s piece on bootstrapping precision machine tools? Go check that out!
Continue reading “Indexing Chuck Not Required”
Do you have a car? Does that car have a manual transmission? Do you want to beautify your shifter knob, while simultaneously gaining mad street cred, yo? Well, you’re in luck, because all of that can be done for the low, low price of a couple old skateboard decks, a lathe, and a lot of glue.
This project, from [basiltab] illustrates how you can use old skateboard decks to create really cool looking custom shifter knobs. The process starts with cutting the decks up into uniform strips, which are then glued and clamped to form small planks. Sections of the decks were alternated, to create a visually interesting pattern. The planks are then sanded so that they’re smooth and flat, and then glued up in a jig to form blocks with a threaded aluminum insert in the center. Optionally, aluminum can be used for some of the layers to add a little flair (2-part epoxy was used in place of glue for the aluminum).
After the glue has dried, the blocks can then be turned on a lathe to create the desired shape of the knob. As you can see, the results are pretty darn nifty. And, they certainly have a little more artistic credibility than the giant acrylic shifter knobs you normally find at your local auto parts store. Don’t worry, if you thought this article was about shift registers, we’ve got you covered there too.
[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!
Continue reading “Simple machining process repairs broken control knob”
[Lindsay Williams] has come up a novel way of constructing custom physical inputs for your programs. SenseSurface is a viable alternative to building a new interface for each application. Simply place the dials, buttons, and sliders on your screen wherever you want them.
A sensor board, placed behind the display, picks up the signals from the inputs. The only limitation to the number of inputs available is the size of your screen. Inputs are held on magnetically, and have a low friction backing to avoid scratching or gouging your screen.
Continue reading “SenseSurface: Custom inputs on your lcd screen”