Plastic Welding Revisited

June 7, 2023 by Al Williams 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.

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BBC Master 128 Revealed

May 28, 2023 by Al Williams 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.

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A Look Inside A Vintage Aircraft Altimeter

May 10, 2023 by Dan Maloney 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 Lewin Day 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.

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Fixing A Reflow Oven’s Conveyer Belt With An NE555 And Stepper Motors

February 23, 2023 by Maya Posch 10 Comments

Some design choices on manufacturing equipment really leave you scratching your head for a while, as recently happened to [Chris Cecil] when the belt on a reflow oven’s conveyer snapped. Although the solution seems simple enough, getting a new belt on the thing would involve essentially taking the entire machine apart, before reassembling it again. Thus the frayed belt went through the oven over and over until during a recent production run of Smoothieboard controller boards until [Chris] heard a funny noise and the conveyer ground to a halt.

Moving the conveyer by hand kind of worked, but with a more permanent fix urgently needed to finish the production run, two stepper motors took the place of the belt, which just left driving these steppers to keep the conveyer moving in sync. Lacking a simple Arduino board to toss at it, and with a Smoothieboard being absolute overkill, [Chris] figured that a humble NE555 timer IC ought to do the job just as well.

Using a project on Hackaday.io by [KushagraK7] as the starting point, and a 1992-vintage NE555 IC harvested from an old project, [Chris] managed to put together a basic stepper driver that uses the NE555 to provide the timing signal. In addition to restoring basic functionality like starting and stopping the conveyer belt, [Chris] added a new feature with the reversing of the conveyer direction. Along with some cobbled together components to physically rotate the conveyer’s two rollers, it restored the reflow oven to working condition.

And one day the prototyped driver board will be updated to a proper PCB. It’s only temporary, after all :)

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Top left of image shows a picture of a purplish-grey sea cucumber. Above the cucumber is the word "bio-inspiration." Arrows come from the cucumber to anthropomorphized cartoons of it saying "rigid" at the top with a cartoon sea cucumber standing straight up with spikes and the arrow captioned "soft" pointing down showing a crawling sea cucumber that looks more like a slug. To the right of the cucumber images is a set of three images stacked top to bottom. The top image is of a silver sphere with a zoomed-in atomic diagram with aligned magnetic poles next to it saying "solid state." The middle image shows arrows going up and down next to a snowflake and an artistic rendering of magnetic fields labeled "transition." The bottom image of this section shows a reddish sphere next to a zoomed-in atomic diagram where the magnetic poles are not aligned labeled "liquid state."

Phase Change Materials For Flexible And Strong Robots

February 19, 2023 by Navarre Bartz 21 Comments

Shape shifters have long been the stuff of speculative fiction, but researchers in China have developed a magnetoactive phase transitional matter (MPTM) that makes Odo slipping through an air vent that much more believable.

Soft robots can squeeze into small spaces or change shape as needed, but many of these systems aren’t as strong as their more mechanically rigid siblings. Inspired by the sea cucumber’s ability to manipulate its rigidity, this new MPTM can be inductively heated to a molten state to change shape as well as encapsulate or release materials. The neodymium-iron-boron (NdFeB) microparticles suspended in gallium will then return to solid form once cooled.

Applications in drug delivery, foreign object removal, and smart soldering (video after the break) probably have more real world impact than the LEGO minifig T1000 impersonation, despite how cool that looks. While a pick-and-place can do better soldering work on a factory line, there might be repair situations where a magnetically-controlled solder system could come in handy.

We’ve seen earlier work with liquid robots using gallium and bio-electronic hybrids also portending the squishy future of robotics.

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A closeup of a black flexible PCB with an out-of-focus quarter in the background, approximately the same size as the end of the PCB we're looking at. One the right is a USB C connector and to its left are two SMD components with visible pins. Several smaller SMD components (resistors or caps?) are soldered to other parts of the board.

Making The AirPods Pro Case Repairable

February 13, 2023 by Navarre Bartz 8 Comments

Apple is often lauded for its design chops, but function is often sacrificed at the altar of form, particularly when repair is involved. [Ken Pillonel] has made it easier for everyone to replace the batteries or lightning port in the AirPods Pro case. (YouTube)

With such notable hacks as adding USB C to the iPhone already under his belt, [Pillonel] has turned his attention to fixing the notoriously poor repairability of AirPods and AirPods Pro, starting with the cases. While the batteries for these devices are available, replacement Lightning ports are not, and taking the housing apart for the case is an exercise in patience where the results can’t be guaranteed.

He designed a USB C replacement port for broken Lightning ports that is a perfect fit if you happen to get the case apart in one piece. If you’re less successful, he has you covered there too with a 3D printable enclosure replacement.

We sure miss the days of schematic proliferation here at Hackaday, but we know you don’t let glued enclosures or unobtainium parts stand in the way of repairs.

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