Exploring Woodworking Mysteries With Strain Gauges And Raspberry Pi

May 3, 2023 by Dan Maloney 19 Comments

If you’re not a woodworker, you might not have heard of the “45-degree rule.” It goes like this: a clamp exerts a force that radiates out across a triangular region of the wood that forms a right angle — 45 degrees on each side of the clamp’s point of contact. So, to ensure that force is applied as evenly as possible across the entire glue joint, clamps should be spaced so that these force triangles overlap. It’s a handy rule, especially for the woodworker looking to justify the purchase of more clamps; you can never have too many clamps. But is it valid?

The short answer that [ari kardasis] comes up with in the video below is… sort of. With the help of a wonderfully complex array of strain gauges and a Raspberry Pi, he found that the story isn’t so simple. Each strain gauge lives in a 3D printed bracket that spaces the sensors evenly along the wood under test, with a lot of work going into making the test setup as stiff as possible with steel reinforcement. There were some problems with a few strain gauges, but once he sorted that out, the test setup went into action.

[ari] tested clamping force transmission through pieces of wood of various widths, using both hardwoods and softwoods. In general, he found that the force pattern is much broader than the 45-degree rule suggests — he got over 60 degrees in some cases. Softwoods seemed to have a somewhat more acute pattern than hardwoods, but still greater than the rulebook says. At the end of the day, it seems like clamp spacing of two board widths will suffice for hardwoods, while 1.5 or so will do for softwoods. Either way, that means fewer clamps are needed.

A lot of woodworking is seat-of-the-pants stuff, so it’s nice to see a more rigorous analysis like this. It reminds us a lot of some of the experiments [Matthia Wandel] has done, like load testing various types of woods and glues.

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Heirloom Knife Will Carve Pumpkins For Years To Come

November 3, 2022 by Kristina Panos 6 Comments

Halloween may be behind us, but that just means that we’ve reached the best time to buy pumpkins. After all, it’s still fall, and there are pies to be made and tables to be decorated. Why should carved-up pumpkins be restricted to spooky season?

The only problem is that it’s 2022, and we’re still expected to use those terrible little serrated knives to carve our pumpkins. Those orange-handled garbage ‘knives’ are hardly suited to cut the lid, much less carve any of the intricate designs that come in the little booklet. So what’s a pumpkin-carving enthusiast to do? If you’re [XYZ Create], you make your own out of walnut, maple, and a gently-used jigsaw blade that’s still way sharp enough to tear through pumpkin flesh.

[XYZ Create] started with a nice chunk of walnut, which he split lengthwise in order to insert the blade, which sits in a cavity within a thin piece of maple. Once [XYZ Create] had the handle ready to go, he inserted the jigsaw blade and epoxied the sandwich together. After sanding down the edges to make a comfortable grip, he finished off the build by rubbing a bit of carving board wax into the handle. Check out the build video after the break.

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Radio Build Goes Outside The Box

June 3, 2021 by Bryan Cockfield 4 Comments

It’s easy to get caught up in a build and forget that the final version usually needs some sort of enclosure, especially things with sensitive electronics in them. The [Director of Legal Evil] at the LVL1 Louisville Hackerspace notes as much in his recent radio build. It seems as though the case was indeed an afterthought, but rather than throwing it in a nondescript black project enclosure it was decided to turn the idea of a project enclosure itself inside-out.

The radio build is based on an SI4732 radio receiver which is a fairly common radio module and is easily adaptable. It needs a microcontroller to run though, so a Maple STM32 platform was chosen to do all of the heavy lifting. The build includes a screen, some custom analog controls, and a small class D audio amplifier, but this is the point it begins to earn its name: the Chaos Radio. While playing around with the project design in CAD, a normal design seemed too bland so one was chosen which makes the radio look like the parts are exploding outward from what would have been a more traditional-style enclosure.

While the project includes a functioning radio receiver, we have to complement the creator for the interesting display style for this particular set of hardware. It can get boring designing the same project enclosures time after time, so anything to shake things up is often welcomed especially when it puts all of the radio components on display like this. In fact, it’s reminiscent of some of [Dmitry]’s projects, an artist known for deconstructing various common household appliances like this CD Player.

Thanks to [Jose] for the tip!

Binary Calculator For All 0b10 Types

November 10, 2020 by Dan Maloney 15 Comments

You know the old joke: There are 10 types of people in the world — those who understand binary, and those who don’t. Most of us on Hackaday are firmly in the former camp, which is why projects like this circuit sculpture binary calculator really tickle our fancies.

Inspired by the brass framework and floating component builds of [Mohit Bhoite], [dennis1a4] decided to take the plunge into circuit sculpture in an appropriately nerdy way. He wisely decided on a starter build, which was a simple 555 timer circuit, before diving into the calculator. Based on an ATMega328P in a 28-pin DIP, the calculator is built on an interesting hybrid platform of brass wire and CNC-routed wood. The combination of materials looks great, and we especially love the wooden keycaps on the six switches that make up the keyboard. There’s also some nice work involved in adapting the TLC5928 driver to the display of 16 discrete LEDs; suspended as it is by fine magnet wires, the SSOP chip looks a bit like a bug trapped in a spider web.

Hats off to [dennis1a4] for a great entry into our soon-to-conclude Circuit Sculpture Contest. The entry deadline is (today!) November 10, so it might be a bit too late for this year. But rest assured we’ll be doing this again, so take a look at all this year’s entries and start thinking about your next circuit sculpture build.

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Making Your Own Maple Syrup Just Got A Little Easier

February 16, 2020 by Lewin Day 23 Comments

[ctstarkdesigns] had fond memories of collecting maple syrup as a child. At the same time, he also remembered the work involved: from lugging buckets around on an unstable snow mobile to accidentally burning the mixture and making all the effort for naught. So he set out to make things a little easier this time around by building his own evaporator.

The build starts as many do, with a surplus 44-gallon drum. With an off-the-shelf kit, and some cutting and welding, it’s readily repurposed into a stove capable of burning wood in a roaring fire. From there, it’s a simple matter of making a few further incisions to install warming trays, used to hold the takings from the maple trees. There, the mixture can be boiled down into the tasty, delicious substance that goes so perfectly on pancakes.

The build has the dual benefits of both easing the boiling process and keeping the user warm while doing so. Already, the rig has proven itself as an adept heater, and we’re sure it will only prove more popular once it’s producing sweet maple syrup en mass. If that’s not enough, consider building an entirely automated system in your back yard!

Hackaday Prize Entry: A Cheap STM32 Dev Board

August 14, 2016 by Brian Benchoff 68 Comments

Dev boards sporting a powerful ARM microcontroller are the future, despite what a gaggle of Arduino clones from China will tell you. Being the future doesn’t mean there’s not plenty of these boards around, though. The LeafLabs Maple has been around since 2009, and is a fine board if you want all that Processing/Wiring/Arduino goodies in a in an ARM dev board. The Maple has been EOL’d, and that means it’s time for a few new boards that build on what LeafLabs left behind.

This Hackaday Prize entry is for an almost-clone of the Leaflabs Maple Mini. It sports a newer microcontroller, but still has the same bootloader and pinout. The best part? It costs less than four dollars.

The microcontroller inside this Maple Mini clone is the STM32F103, a 32-bit ARM Cortex-M3 running at 72 MHz with 128K of Flash and 20K of SRAM. That’s enough for just about everything you would want to throw at it. It also follows the pinout of the original Maple Mini, and the team also has a version that’s a slight improvement of the original Maple.

The big deal is, of course, the price of the board. It’s four bucks, or about the same price as an Arduino clone from the usual online retailers. Now, finally, there’s a reason for you to wash your hands of the Arduino too.

Field Expedient Bandsaw Mill Deals With Leftover Logs

May 21, 2016 by Dan Maloney 22 Comments

When a questionable tree threatened his house, [John Heisz] did the sensible thing and called in a professional to bring it down. But with a flair for homebrew tools, [John] followed up with a seemingly non-sensible act and built a quick and dirty DIY bandsaw mill to turn the resulting pile of maple logs into usable lumber.

A proper bandsaw mill is an expensive tool. Prices start in the mid-four figures for a stripped down version and can easily head into the multiple tens of thousands for the serious mills. [John] makes it clear that his mill is purpose-built to deal with his leftover logs, and so he made no attempt at essentials like a way to index the blade vertically. His intention was to shim the logs up an inch after each cut, or trim the legs to move the blade down. He also acknowledges that the 2-HP electric motor is too anemic for the hard maple logs – you can clearly see the blade bogging down in the video below. But the important point here is that [John] was able to hack a quick tool together to deal with an issue, and in the process he learned a lot about the limitations of his design and his choice of materials. That’s not to say that wood is never the right choice for tooling – get a load of all the shop-built tools and jigs in his build videos. A wooden vise? We’d like to see the build log on that.

We’ve featured a surprising number of wooden bandsaws before, from benchtop to full size. We’re pretty sure this is the first one purpose built to mill logs that we’ve featured, although there is this chainsaw mill that looks pretty handy too.

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