repair

248 Articles

Nail, Meet KiCad

July 24, 2023 by 25 Comments

You know the old saying. When all you have open is KiCad, everything looks like a PCB. That was certainly true for [Evan], who needed to replace a small part recently and turned to PCBs to get the job done.

The part in question was a sheered apart detent cam from a retractable cord reel. Glue and epoxy might have worked, and [Evan] was worried about how a 3D printed PLA part would have held up. The part is an extruded 2D shape, making PCBs a non-traditional but viable choice. Using the old scanner trick, he traced the outline in KiCad 7 (which adds image references). Then with the five boards stacked up, solid core wire, solder, and a propane torch worth of heat fused it. Ultimately, this machine’s tolerances are generous, so it worked wonderfully.

Was it the “right” tool for the job? Right or wrong, it is hard to argue that in terms of durability and ease per dollar, this doesn’t come out on top. PCB files are on GitHub if you have a 5020TF-4c retractable cord reel that needs a new cam. PCBs have a fun way of adopting different use cases like enclosures, but perhaps the idea of PCBs as a mechanical part could be applied elsewhere.

Do Not Attempt Disassembly: Analog Wizardry In A 1960s Counter

June 12, 2023 by 22 Comments

[CuriousMarc] is back with more vintage HP hardware repair. This time it’s the HP 5245L, a digital nixie-display frequency counter from 1963. This unit is old enough to be entirely made of discrete components, but has a real trick up its sleeve, with add-on components pushing the frequency range all the way up to 18 GHz. But this poor machine was in rough shape. There were previous repair attempts, some of which had to be re-fixed with proper components. When it hit [Marc]’s shop, the oscillator was working, as well as the frequency divider, but the device wasn’t counting, and the reference frequencies weren’t testing good at the front of the machine. There were some of the usual suspects, like blown transistors. But things got really interesting when one of the boards had a couple of tarnished transistors, and a handful of nice shiny new ones — but maybe not all the right transistors. Continue reading “Do Not Attempt Disassembly: Analog Wizardry In A 1960s Counter” →

Plastic Welding Revisited

June 7, 2023 by 27 Comments

Last time we talked about a video that purported to do plastic welding, we mentioned that the process wasn’t really plastic welding as we understood it. Judging by the comments, many people agreed, but it was still an interesting technique. Now [Inventor 101] has a video about plastic repair that also talks about welding, although — again, we aren’t sure all of the techniques qualify.

That’s not to say there aren’t some clever ideas, though. There are several variations on a theme, but the basic idea is to use a bolt or something similar in a soldering iron, metal reinforcement from things like wires and staples, and donor plastic from a zip tie. While we don’t think the nylon in a typical zip tie is the best way to repair anything other than nylon, if you were repairing something 3D printed, you could easily swap out the tie for filament of the same material, which — we think — would bond better.

Continue reading “Plastic Welding Revisited” →

BBC Master 128 Revealed

May 28, 2023 by 12 Comments

[Adrian] comments that the BBC Master 128 is a rare 8-bit computer, and we agree — we couldn’t remember hearing about that particular machine, although the BBC series is quite familiar. The machine has a whopping 128 K of RAM, quite a bit for those days. It also had a 6502 variant known as the 65C12, which has an extra pin compared to a 6502 and doesn’t use the same clock arrangement. A viewer sent him one of these machines, which apparently was used in the BBC studios. You can see this rare beauty in the video below.

The computer has a very nice-looking keyboard that includes a number pad. There are also expansion ports for printers and floppy disk drives. It has some similarities to a standard BBC computer but has a number of differences externally and internally.

Of course, we were waiting for the teardown about 15 minutes in. There were some corroded batteries but luckily, they didn’t do much damage. The power supply had a burned smell. Cracking it open for inspection was a good time to convert the power supply to run on 120 V, too.

After some power supply repair, it was time to power the machine up. The results were not half bad. It started up with a cryptic error message: “This is not a language.” Better than a dead screen. The keyboard wasn’t totally working, though. A bit of internet searching found that the error happens when the battery dies and the machine loses its configuration.

More walkthroughs will take a bit more work on the keyboard. But we were impressed it came up as far as it did, and we look forward to a future installment where the machine fully starts up.

[Adrian] mentioned the co-processor slot accepting a Raspberry Pi, something we’ve talked about before. Or, add an FPGA and make the plucky computer think it is a PDP/11.

Continue reading “BBC Master 128 Revealed” →

A Look Inside A Vintage Aircraft Altimeter

May 10, 2023 by 21 Comments

There’s a strange synchronicity in the projects we see here at Hackaday, where different people come up with strikingly similar stuff at nearly the same time. We’re not sure why this is, but it’s easily observable, with this vintage altimeter teardown and repair by our good friend [CuriousMarc] as the latest example.

The altimeter that [Marc] dissects in the video below was made by Kollsman, which is what prompted us to recall this recent project that turned a jet engine tachometer into a CPU utilization gauge. That instrument was also manufactured by Kollsman, but was electrically driven. [Marc]’s project required an all-mechanical altimeter, so he ordered a couple from eBay.

Unfortunately, thanks to rough handling in transit they arrived in less than working condition, necessitating the look inside. For which we’re thankful, of course, because the guts of these aneroid altimeters are quite impressive. The mechanism is all mechanical, with parts that look like something [Click Spring] would make for a fine timepiece. [Marc]’s inspection revealed the problem: a broken pivot screw keeping the expansion and contraction of the aneroid diaphragms from transmitting force to the gear train that moves the needles. The repair was a little improvisational, with 0.5-mm steel balls used to stand in for the borked piece. It may not be flight ready, but it worked well enough to get the instrument back in action.

We suspect that [Marc] won’t be able to leave well enough alone on this one, so we’ll be on the lookout for a proper repair. In the meantime, he’ll be able to use this altimeter in the test setup he’s building to test a Bendix air data computer from a 1950s-era jet fighter. Continue reading “A Look Inside A Vintage Aircraft Altimeter” →

This One Simple Trick Rehabilitates Scratchy Sounding Speakers

April 20, 2023 by 13 Comments

We’ve all picked up a radio and switched it on, only to hear an awful scratchy noise emitting from the speaker. [Richard Langer] is no stranger to this problem, and has identified a cheap and unusual solution—using toilet paper!

The cause of the scratchy sound is that when the speaker’s paper cone warps, it can cause the voice coil to rub up against the magnet assembly. In time, this wears out insulation on the coil’s turns, damaging the speaker. [Richard] found that realigning the coil to its proper place would rectify the issue. This can be achieved by stuffing a small amount of toilet paper in the back of the speaker, between the cone and the metal housing.

To identify the right spot to put the paper, one simply presses on the back of the speaker with a pen while listening out for the scratchy sound to stop. The paper can then be stuffed into this area to complete the fix. This can realign the cone and voice coil and stop the scratchy sound for good.

[Richard] notes that this method can be quite long-lasting in some cases. Failing that, it should serve long enough for you to order a replacement speaker. Video after the break.

Continue reading “This One Simple Trick Rehabilitates Scratchy Sounding Speakers” →