Makerpipe Turns Conduit Into Structures

September 27, 2024 by Dan Maloney 25 Comments

At the risk of stating the obvious, building big things can be difficult. Sure, parts that fit on the bed of a 3D printer are easy to make, if not particularly fast, and scaling up from there is possible. But if you need a long beam or structural element, printing makes little sense; better to buy than build in that case. The trouble then becomes, how do you attach such parts together?

Enter Makerpipe. This South Carolina company, recently out of a crowdfunding campaign, makes a range of structural connectors and fittings for electrical mechanical tubing, or EMT, the galvanized steel conduit used in the electrical trades. EMT is widely available in multiple sizes and is relatively cheap, although we have noticed that the price here has ticked up quite a bit over the last couple of years. It also has the advantage of being available off-the-shelf at any big-box home improvement store, meaning you have instant access to a fantastic building material.

Makerpipe’s bolt-together couplings let you turn pieces of EMT, easily cut with a hacksaw or pipe cutter, into structures without the need for welding. Yes, you can do the same with extruded aluminum, but even if you’re lucky enough to live near a supply house that carries extrusions and the necessary fittings and is open on Saturday afternoon, you’ll probably pay through the nose for it.

Makerpipe isn’t giving their stuff away, and while we normally don’t like to feature strictly commercial products, something that makes building large structures easier and faster seems worth sharing with our community. We’ve done our share of fabricobbling together EMT structures after all, and would have killed for fittings like these.

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DIY Airless Tires Work Surprisingly Well

June 30, 2022 by Bryan Cockfield 47 Comments

Airless tires have been “a few years away” from production for decades now. They’re one of the automotive version of vaporware (at least those meant for passenger vehicles), always on the cusp of being produced but somehow never materializing. They have a number of perks over traditional air-filled tires in that they are immune to flats and punctures, and since there aren’t any airless tires available at the local tire shop, [Driven Media] decided to make and test their own.

The tires are surprisingly inexpensive to make. A few pieces of drainage tubing of varying diameters, cut to short lengths, and then bolted together with off-the-shelf hardware is all it takes, although they note that there was a tremendous amount of hardware needed to fasten all the pipe lengths together. With the structure in place they simply cut a tread off of a traditional tire and wrapped it around each of the four assemblies, then bolted them up to their Caterham street-legal race car for testing.

While the ride quality was notoriously (and unsurprisingly) rough and bumpy, the tires perform admirably under the circumstances and survive being driven fairly aggressively on a closed-circuit race course. For such a low price and simple parts list it’s shocking that a major tire manufacturer like Michelin hasn’t figured out how to successfully bring one to a light passenger car yet.

Thanks to [Itay] for the tip!

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PVC Pipe Transformed Into Handy Tool Box

June 15, 2022 by Tom Nardi 18 Comments

Would you believe the multi-tiered toolbox pictured here started its life as a piece of bog standard PVC pipe? It certainly wouldn’t be our first choice of building material, but as shown in the video after the break, it only takes a heat source and something suitably flat to convert a piece of PVC pipe into a versatile sheet material.

Unrolling the PVC pipe and getting it flat is covered in the first minute of the video, while the rest of the run time is dedicated to building the tool box. Each and every piece you see here, except for the screws and lid hinges, is carefully cut from the PVC sheet. Though we suspect a few more chunks of pipe went into this build than the video would have you believe.

Would we build such an elaborate box if we had to cut each piece of the thing out by hand? Probably not. But then, we can’t deny the final results here are pretty impressive. Incidentally, if you thought those hinges on the top looked a lot like links removed from a watch band…you’d be correct.

Admittedly we’re a bit late covering this one, and under normal circumstances we might have let it slip by given the several million views it’s amassed over the last year. But the central theme of reusing a common material to build something unexpected is solid Hackaday territory, and aligns closely with this year’s Hackaday Prize challenges.

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Retrotechtacular: Clay Pipe The Hard Way

May 31, 2022 by Dan Maloney 28 Comments

Troll YouTube long enough and chances are good that you’ll come across all kinds of videos of the “How It’s Made” genre. And buried in with the frying pans and treadmills and dental floss manufacturers, there no doubt will be deep dives on how pipe is made. Methods will vary by material, but copper, PVC, cast iron, or even concrete, what the pipe factories will all have in common is the high degree of automation they employ. With a commodity item like pipe, it’s hard to differentiate yourself from another manufacturer on features, so price is about the only way to compete. That means cutting costs to the bone, and that means getting rid of as many employees as possible.

Such was not always the case, of course, as this look at how Irish Stoneware & Fireclays Ltd. made clay pipe, drain tiles, and chimney flues back in the 1980s shows. The amount of handwork involved in making a single, simple piece of clay pipe is astonishing, as is the number of hands employed at the various tasks. The factory was located in Carrickmacross, County Monaghan, Ireland, near an outcropping of shale that forms the raw material for its products. Quarrying the shale and milling it into clay were among the few mechanized steps in the process; although the extrusion of the pipe itself was also mechanized, the machines required teams of workers to load and unload them.

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Heating A Home With Sunlight… And Water

April 22, 2021 by Bryan Cockfield 64 Comments

The sun is a tremendous source of energy, and while photovoltaic panels are an easy way to harvest some of that energy especially now that prices for them are incredibly low, there are plenty of other ways to tap into that free energy as well. [Engelbert] was looking for alternative ways to heat his house since traditional methods were prohibitively expensive, and ended up building a heat exchanger using solar-heated water to cover his home heating needs. (Google Translate from Dutch)

The system uses several large roof-mounted hot water heating panels. The heat captured by them is then pumped into an underground pipe network which is able to warm up a large area of earth in the summer. In the winter, that heat is able to be extracted back out of the earth and used to heat his home. The system includes almost three kilometers of pipe which are buried two meters below grade, so this will probably not be a weekend project, but it still cost much less than the €80,000 to install gas heating in his home.

[Engelbert] is able to use this self-built system to keep his home and another smaller building at a constant 23°C all year. He actually overbuilt the system slightly and has since disconnected almost half of the pipes, but we certainly understand the desire to over-engineer things around here. The only problem he has had is with various government entities that are slow to adopt energy-efficient systems like these. Perhaps the Dutch government can take some notes from the Swiss when it comes to installing geothermal systems like these.

Thanks to [Jero] for the tip!

Hydraulics Made Simple

April 7, 2021 by Al Williams 5 Comments

Corralling electrons is great and what most of us are pretty good at, but the best projects have some kind of interface to the real world. Often, that involves some sort of fluid such as water or air moving through pipes. If you don’t grasp hydraulics intuitively, [Practical Engineering] has a video you’ll enjoy. It explains how flow and pressure work in pipes.

Granted, not every project deals with piping, but plumbing, sprinkler systems, cooling systems, and even robotics often have elements of hydraulics. In addition, as the video points out, fluid flow in a pipe is very similar to electrical current flowing through wires.

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The Ground Beneath Your Feet: SuperAdobe Construction

October 27, 2020 by Bryan Cockfield 25 Comments

Homes in different parts of the world used to look different from each other out of necessity, built to optimize for the challenges and benefits of local climate. When residential climate control systems became commonplace that changed. Where a home in tropical south Florida once required very different building methods (and materials) compared to a home in the cold mountains of New England, essentially identical construction methods are now used for single-family homes in any climate. The result is inefficient and virtually indistinguishable housing from coast to coast, regardless of climate. As regions throughout the world are facing increasingly dire housing shortages, the race is on to find solutions that are economical and available to us right now.

The mission of CalEarth, one of the non-profits that Hackaday has teamed up with for this year’s Hackaday Prize, is to address that housing shortage by building energy-efficient homes out of materials already available in the areas that they will be built. CalEarth specializes in building adobe, or earth, homes that have a large thermal mass and an inexpensive bill of materials. Not only does this save on heating and cooling costs, but transportation costs for materials can be reduced as well. Some downside to this method of construction are increased labor costs and the necessity of geometric precision of the construction method, both of which are tackled in this two-month design challenge.

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