Solenoid Engine Adds Three “Pistons”

October 28, 2019 by Bryan Cockfield 9 Comments

The earliest piston engines typically had only one cylinder, and at best, produced horsepower measured in single digits. But once you have a working engine, it’s a relatively short step to adding cylinders and increasing the power output. [Emiel] made a similar upgrade to one of his engines recently, upgrading it from one cylinder to four. But this isn’t an internal combustion engine, it gets its power from electric solenoids.

We featured his single-cylinder build about a month ago, and since then he’s been busy with this impressive upgrade. The new engine features four cylinders arranged in a V4 pattern. Of course, this greatly increases the mechanical complexity. To start, he had to machine a crankshaft to connect all four “pistons” to a shared output shaft. He also had to build a set of cams in order to time the firing of the cylinders properly, so they don’t work against one another.

The build is just as polished and impressive as the last, which is saying a lot. [Emiel] has a quality machine shop and built the entire motor from scratch, including winding the solenoids, machining the connecting rods and shafts, and building a very picturesque wooden base for the entire contraption to sit on. It’s definitely worth checking out.

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Making A Bronze Cannon From Scratch

October 27, 2019 by Danie Conradie 18 Comments

Casting metal at home is somewhat tricky, but there’s no denying the results can be quite rewarding. [FarmCraft101] put his incredible craftsmanship on display, and learned a few new things in the process, by scratch building a scale replica bronze cannon and carriage.

Starting with a sufficient quantity of scrap metal, he first produced bronze ingots. Getting the actual casting right took multiples attempts. First tried a lost foam cast, which failed miserably, but provided a sample metal which was put through tensile strength testing. The second attempt was done using a wood barrel form and a split mold, and was cast horizontally which resulted in shrinkage on top of the barrel. The third attempt, arranged vertically, almost resulted in a high risk game of “the floor is lava”, with molten bronze pouring out across his garage floor after the mold split open during casting.

Attempt number four was finally successful, again using a vertical mold but with more sturdy clamping. This roughcast barrel was then drilled out and finished to a beautiful mirror with the help of a lathe and a lot of elbow grease. He then turned his attention to the carriage, which itself is a real beauty featuring custom wagon wheels with a charred wood finish and linseed oil coating.

You can check out the build video after the break, but we’ll warn you now, [FarmCraft101] never actually fires this gorgeous creation. If you’d like to try your hand at DIY cannoneering and have a 3D printer, you might want to give lost PLA casting a try, or go into mass production with some DIY silicone molds.

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A Double-Hybrid Mini-Lathe, From Scratch

October 23, 2019 by Dan Maloney 4 Comments

It’s a treadle lathe! No, it’s a power lathe! It’s a wood lathe! No, it’s a metal lathe! Actually, [Uri Tuchman]’s homebrew lathe is all of the above, and it looks pretty snazzy too.

To say that [Uri]’s creations are quirky is a bit of an understatement – birds, crustaceans, hands, and feet all appear repeatedly as motifs in his work – but there’s no overstating his commitment to craftsmanship. [Uri] turns wood and metal into wonderful tools, nonsense machines, and finely detailed instruments, like this exquisitely engraved astrolabe we featured a while back.

[Uri] mostly works with hand tools, supplemented by an old Singer treadle-powered sewing machine that he turned into a scroll saw. The video below shows how he added a small scratch-built lathe to the treadle base. His first pass at a headstock, using pillow blocks for bearings, didn’t work as well as he wanted, so he built a new headstock around off-the-shelf lathe parts. The aluminum extrusion bed holds the headstock, tailstock, and a custom-built tool rest of heavy brass, all of which look great alongside the rich wood accent pieces and base. And for those times when his feet are tired, he added a surplus electric motor to turn the spindle. We especially like the two settings on the motor speed control: “0” and “>0”. Classic [Uri].

If you haven’t heard of [Uri] before, do yourself a favor and go check out his YouTube channel right now. Or start with our other coverage of his unique projects, from building an intricately detailed hammer to his lobster claw ink-dipping machine and even this unusual take on preserved lemons.

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Build Your Own Solenoid Engine

September 25, 2019 by Bryan Cockfield 13 Comments

A solenoid engine is a curiosity of the electrical world. By all measures, using electricity to rotate something can be done almost any other way with greater efficiency and less hassle. But there’s just something riveting about watching a solenoid engine work. If you want to build one of your own and see for yourself, [Emiel] aka [The Practical Engineer] has a great how-to.

For this build though he used a few tools that some of us may not have on hand, such as a lathe and a drill press. The lathe was used to make the plastic spool to hold the wire, and also to help wind the wire onto the spool itself rather than doing it by hand. He also milled the wood mounts and metal bearings as well, and the quality of the work really shows through in the final product. The final touch is the transistor which controls power flow to the engine.

If you don’t have all of the machine tools [Emiel] used it’s not impossible to find substitute parts if you want to build your own. It’s an impressive display piece, or possibly even functional if you want your build to have a certain steampunk aesthetic (without the steam). You can even add more pistons to your build if you need extra power.

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Bend Some Bars With A Flywheel

September 25, 2019 by Danie Conradie 16 Comments

The ability to look at a pile of trash, and see the for treasure is a skill we hold in high regard around here. [Meanwhile in the Garage] apparently has this skill in spades and built himself a metal bar bending machine using an old flywheel and starter pinion gear.

To bend metal using muscle power alone requires some sort of mechanical advantage. Usually this involves a bending tool with a long lever, but [Meanwhile in the Garage] decided to make use of the large gear ratio between a car’s starter motor and the flywheel it drives. This does away with the need for a long lever and allows bending to almost 270° with a larger radius. Lathe and milling work features quite prominently, including to make the bend formers, drive shaft and bushings and to modify the flywheel to include a clamp. The belt sander that is used to finish a number of the parts is also his creation. While the machine tools definitely helped, a large amount of creativity and thinking outside the box made this project possible and worth the watch.

We’ve featured a number of scrap-built tools including a milling machine, sheet metal hole punch and a hydraulic bench vice. Keep them coming!

Scrapyard Milling Machine Gets Work Done On A Budget

September 1, 2019 by Dan Maloney 22 Comments

Which to buy first, a lathe or a mill? It’s a tough question for the aspiring home machinist with limited funds to spend on machine tools, but of course the correct answer is a lathe. With a lathe, we are told, all other machine tools can be built, including a milling machine. Granted that might be a slight exaggeration, but [Maximum DIY] was still able to use his budget-blowing lathe to make a decent milling machine mostly from scrap.

Details are a bit sparse in the forum post, but there’s enough there and in the video after the break to be mightily impressed with the build. Unlike many DIY mills that are basically modified drill presses, [Maximum DIY] started with things like a scrapped bench grinder pedestal and surplus steel tubing. The spindle motor is from a paint sprayer and the Z-axis power feed is a treadmill incline motor. The compound table was a little too hard to make, so the purchased table was fitted with windshield wiper motor power feeds.

Therein lies perhaps the most clever hack in this build: the use of a plain old deep 19mm socket as a clutch for the power feeds. The 12-point socket slides on the square shaft of the wiper motor to engage the drive screw for the compound table – simple and bulletproof.

To be sure, the finished mill is far from perfect. It looks like it needs more mass to quell vibration, and those open drive pulleys are a little nerve wracking. But it seems to work well, and really, any mill is better than no mill. Of course, if you’re flush with cash and want to buy a mill instead of making one, this buyer’s guide should help.

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Hackaday Links: July 21, 2019

July 21, 2019 by Dan Maloney 17 Comments

Ordering a PCB used to be a [Henry Ford]-esque experience: pick any color you like, as long as it’s green. We’ve come a long way in the “express yourself” space with PCBs, with slightly less than all the colors of the rainbow available, and some pretty nice silkscreening options to boot. But wouldn’t it be nice to get full-color graphics on a PCB? Australian company Little Bird thinks so, and they came up with a method to print graphics on a board. The results from what looks like a modified inkjet printer are pretty stunning, if somewhat limited in application. But I bet you could really make a splash with these in our Beautiful Hardware contest.

The 50th anniversary of the Apollo 11 landing has come and gone with at least as much fanfare as it deserves. Part of that celebration was Project Egress, creation of a replica of the Columbia crew hatch from parts made by 44 hackers and makers. Those parts were assembled on Thursday by [Adam Savage] at the National Air and Space Museum in an event that was streamed live. A lot of friends of Hackaday were in on the build and were on hand, like [Fran Blanche], [John Saunders], [Sophy Wong], and [Estefannie]. The Smithsonian says they’ll have a recording of the stream available soon, so watch this space if you’re interested in a replay.

From the “Don’t try this at home” department, organic chemist [Derek Lowe] has compiled a “Things I won’t work with” list. It’s real horror show stuff that regales the uninitiated with all sorts of chemical nightmares. Read up on chlorine trifluoride, an oxidizer of such strength that it’s hypergolic with anything that even approaches being fuel. Wet sand? Yep, bursts into flames on contact. Good reading.

Continuing the safety theme, machinist [Joe Pieczynski] offers this lathe tip designed to keep you in possession of a full set of fingers. He points out that the common practice of using a strip of emery cloth to polish a piece of round stock on either a wood or metal lathe can lead to disaster if the ends of the strip are brought into close proximity, whereupon it can catch and act like a strap wrench. Your fingers don’t stand a chance against such forces, so watch out. [Joe] doesn’t share any gory pictures of what can happen, but they’re out there. Only the brave need to Google “degloving injury.” NSFL – you’ve been warned.

On a happier note, wouldn’t it be nice to be able to print water-clear parts on a standard 3D printer? Sure it would, but the “clear” filaments and resins all seem to result in parts that are, at best, clearish. Industrial designer [Eric Strebel] has developed a method of post-processing clear SLA prints. It’s a little wet sanding followed by a top coat of a super stinky two-part urethane clearcoat. Fussy work, but the results are impressive, and it’s a good technique to file away for someday.