If you’re looking for the perfect excuse to buy that big, beautiful Bridgeport mill, we’ve got some bad news: it’s not going to be making perfectly square end cuts on aluminum extrusion. Sadly, it’s much more cost-effective to build this DIY squaring jig, and search for your tool justification elsewhere.
There’s no doubting the utility of aluminum extrusion in both prototyping and production builds, nor that the versatile structural members often add a bit of class to projects. But without square cuts, any frames built from them can be seriously out of whack, leading to misery and frustration down the road. [Midwest Cyberpunk]’s mill-less solution uses a cheap Harbor Freight router as a spindle for a carbide endmill, riding on a laser-cut acrylic baseplate fitted with wheels that ride in the V-groove of — you guessed it — aluminum extrusions. A fence and clamping system holds the extrusion firmly, and once trammed in, the jig quickly and easily squares extrusions that have been rough cut with a miter saw, angle grinder, or even a hacksaw. Check out the video below for a peek at the build details.
We love the simplicity and utility of this jig, but can see a couple of areas for improvement. Adding some quick-throw toggle clamps would be a nice touch, as would extending the MDF bed and fence a bit for longer cuts. But even as it is, this tool gets the job done, and doesn’t break the bank like a mill purchase might. Still, if your heart is set on a mill, who are we to stand in the way?
One of the knocks that woodworkers get from the metalworking crowd is that their chosen material is a bit… compliant. Measurements only need to be within a 1/16th of an inch or so, or about a millimeter, depending on which side of the Atlantic you’re on. And if you’re off a bit? No worries, that’s what sandpaper is for.
This electronic router lift is intended to close the precision gap and make woodworking a bit less subjective. [GavinL]’s build instructions are clearly aimed at woodworkers who haven’t dabbled in the world of Arduinos and stepper motors, and he does an admirable job of addressing the hesitancy this group might feel when tackling such a build. Luckily, a lot of the mechanical side of this project can be addressed with a commercially available router lift, which attaches to a table-mounted plunge router and allows fine adjustment of the cutting tool’s height from above the table.
What’s left is to add a NEMA 23 stepper to drive the router lift, plus an Arduino to control it. [GavinL] came up with some nice features, like a rapid jog control, a fine adjustment encoder, and the ability to send the tool all the way up or all the way down quickly. Another really nice touch is the contact sensor, which is a pair of magnetic probes that attach temporarily to the tool and a height gauge to indicate touch-off. Check the video below to see it all in action.
One quibble we have with [GavinL]’s setup is the amount of dust that the stepper will be subjected to. He might need to switch out to a dustproof stepper sooner rather than later. Even so, we think he did a great job bridging the gap between mechatronics and woodworking — something that [Matthias Wandel] has been doing great work on, too.
We’re no strangers to [Ivan]’s work and this time he’s building a relatively small CNC machine using extrusion, 3D printed parts, and a Makita router. The plans are available at a small cost, but just watching the accelerated build is fascinating.
You might think you could just attach something to an existing 3D printer frame that cuts like a Dremel tool. You can do that, but for most purposes, you need something stiffer than most desktop printers. You can see how solid this build is with multiple extrusions forming the base and very rigid axes.
Judging from the video, the machine made short work of some aluminum plate. Of course, some of that is in the choice of tool, but it appears the machine is stable enough to hold the workpiece and the tool stable to allow this sort of service. [Ivan] says the machine cost him about 600 Euro ($670 USD) and you need a printer that can create parts as large as 180 x 180 mm.
There are quite a few similar mostly 3D printed machines on Thingiverse, including some that have been through multiple versions. If you have an old 3D printer sitting around for parts, you may have nearly everything you need if you add some printed parts, presumably from your new printer.
We like projects where old gear is given a new life. [Splashdust] has a twenty-year old business firewall that’s build like a tank. He cracks it open and finds a complete x86 embedded motherboard inside, and sets off to restore it and turn it into a retro gaming computer (see the video from his Odd & Obsolete YouTube channel below the break).
This business firewall and router box is from a small Swedish firm Clavister, part of their S-Series from the early 2000s. The motherboard appears to be a generic one used in other equipment, and is powered by a VIA Eden ESP 4000 running at 400 MHz. The Eden line of x86 processors were low-power chips targeting embedded applications. The graphics chip is a Twister T by S3 Graphics which was purchased by VIA in 2000. After replacing the electrolytic capacitors, and making a few cables, [Splashdust] pops in a PCI sound card and boots up into Windows 98 from a CF card (we like the compact PCB vise he uses).
In two follow-up videos (here and here), he builds an enclosure (instructions on Thingiverse) and tries out several other operating systems. He was able to get the Tiny Core Linux distribution running with the NetSurf browser, but failed to get Windows 2000 or XP to work. Returning to Windows 98, he tweaks drivers and settings and eventually has a respectable retro-gaming computer for his efforts. The next time you’re cleaning out your junk bins, have a peek inside those pizza-box gadgets first — you may find a similar gem.
It would be fair to say that the Internet as we know it runs on Cisco hardware. While you might never see the devices first-hand, there’s an excellent chance that every web-bound packet leaving your computer or smartphone will spend at least a few milliseconds of its life traveling through hardware built by the San Jose, California based company. But of course, even a telecommunications giant like Cisco had to start somewhere.
Cisco’s first commercial router, the Advanced Gateway Server (AGS), was released in 1986 and helped put the company (and the Internet) on the path towards unfathomable success. [Andreas Semmelmann] had wanted to add one of these microwave-sized machines to his collection for some time, so when an AGS+ popped up in the local classifieds he didn’t hesitate to make the hour drive to go pick it up. But like many pieces of vintage computing equipment, it needed a little help getting back on its feet.
What 4 MB of flash looked like in the late 1980s.
Since he had to take the router apart anyway to diagnose what ailed it, [Andreas] decided to take photographs along the way and document this piece of Internet history. He walks the reader through the massive processor, Ethernet, and serial cards that are housed in the unit’s rack-like enclosure. We appreciate him taking the scenic route, as it gives us a great look inside what would have been state-of-the-art telecommunications gear when this version of the AGS hit the market in 1989.
The walk-through is full of interesting details that make us appreciate just how far things have come in the last 32 years. Imagine yanking the EPROMs out of the board and firing up the UV eraser each time you needed to update your router’s firmware. Or needing a special adapter to convert the AUI-15 connectors on the back panel to the now ubiquitous RJ45 jack.
After this stroll down memory lane, [Andreas] gets to the actual repair work. It likely won’t surprise the regular Hackaday reader to find that the power supply wasn’t operating to spec, and that some aged capacitors and a shorted rectifier diode needed to be replaced to put it back on an even keel. But even with the PSU repaired, the router failed to start. The console output indicated the software was crashing, but hardware diagnostics showed no obvious faults.
Replacing these failed PSU components was just the beginning.
With some part swapping, firmware flashing, and even a bit of assistance from Cisco luminary [Phillip Remaker], the issue was eventually identified as a faulty environmental monitoring (ENVM) card installed in the AGS+. As luck would have it the ENVM capability isn’t required to boot the router, so [Andreas] was able to just disconnect the card and continue on with his exploration of the hardware that helped build the Internet as we know it.
For years, Europeans have been browsing the central aisles of the German Aldi and Lidl supermarket chains, attracted by the surprising variety of transitory non-grocery bargains to be found there. There are plenty of temptations for hackers, and alongside the barbecues and Parkside tools at Lidl last year was a range of Zigbee home automation products. Every ZigBee network requires some form of hub, and for Lidl this comes in the form of a £20 (about $28) Silvercrest Home Gateway appliance. It’s a small embedded Linux computer at heart, and [Paul Banks] has published details of how it can be hacked and bent to the user’s will.
Under the hood is a Realtek RTL8196E MIPS SoC with 16Mb of Flash and 32 Mb of memory. Gaining control of it follows the well trodden path of finding the bootloader, dumping the firmware, and re-uploading it with a known password file. If you’ve done much hacking of routers and the like you’ll recognise that this quantity of memory and Flash isn’t the most powerful combination so perhaps you won’t be turning it into a supercomputer, but it’s still capable enough to be integrated with Home Assistant rather than the cloud-based services with which it shipped.
There was a time when repurposing routers as embedded Linux machines was extremely popular, but it’s something that has fallen from favour as boards such as the Raspberry Pi have provided an easier path. So it’s good to see a bit of old-fashioned fun can still be had with an inexpensive device.
Key to achieving the hack was finding a way to remove the existing NAND flash in the working router without crashing the system while doing so. This required careful disconnection of the chip’s power lines once the router had booted up, as well as tying the “Ready/Busy” and “Read Enable” pins to ground. With this done, the chip could carefully be removed with a hot air tool without disrupting the router’s operation. The new chip could then be soldered in place, and flashed with factory firmware via the router’s web interface. At this point, it could be powered down and the chips swapped normally back into their own respective routers, restoring both to full functionality.
