The Hacky Throttle Repair That Got Me On The Road Again

June 6, 2018 by Lewin Day 82 Comments

Old cars are great. For the nostalgia-obsessed like myself, getting into an old car is like sitting in a living, breathing representation of another time. They also happen to come with their fair share of problems. As the owner of two cars which are nearing their 30th birthdays, you start to face issues that you’d never encounter on a younger automobile. The worst offender of all is plastics. Whether in the interior or in the engine bay, after many years of exposure to the elements, parts become brittle and will crack, snap and shatter at the slightest provocation.

You also get stuck bolts. This was the initial cause of frustration with my Volvo 740 Turbo on a cold Sunday afternoon in May. As I tried in vain to free the fuel rail from its fittings, I tossed a spanner in frustration and I gave up any hope of completing, or indeed, starting the job that day. As I went to move the car back into the driveway, I quickly noticed a new problem. The accelerator was doing approximately nothing. Popping the hood, found the problem and shook my head in resignation. A Volvo 740 Turbo is fitted with a ball-jointed linkage which connects the accelerator cable to the throttle body itself. In my angst, the flying spanner had hit the throttle body and snapped the linkage’s plastic clips. It was at this point that I stormed off, cursing the car that has given me so much trouble over the past year.

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Micro Chainsaw Gets A Much Needed Nitro Power Boost

April 10, 2018 by Dan Maloney 25 Comments

When life hands you the world’s smallest chainsaw, what’s there to do except make it even more ridiculous? That’s what [JohnnyQ90] did when he heavily modified a mini-electric chainsaw with a powerful RC car engine.

The saw in question, a Bosch EasyCut with “Nanoblade technology,” can only be defined as a chainsaw in the loosest of senses. It’s a cordless tool intended for light pruning and the like, and desperately in need of the [Tim the Toolman Taylor] treatment. The transmogrification began with a teardown of the drivetrain and addition of a custom centrifugal clutch for the 1.44-cc nitro RC car engine. The engine needed a custom base to mount it inside the case, and the original PCB made the perfect template. The original case lost a lot of weight to the bandsaw and Dremel, a cooling fan was 3D-printed, and a fascinatingly complex throttle linkage tied everything together. With a fuel tank hiding in the new 3D-printed handle, the whole thing looks like it was always supposed to have this engine. The third video below shows it in action; unfortunately, with the engine rotating the wrong direction and no room for an idler gear, [JohnnyQ90] had to settle for flipping the bar upside down to get it to cut. But with some hacks it’s the journey that interests us more than the destination.

This isn’t [JohnnyQ90]’s first nitro rodeo — he’s done nitro conversions on a cordless drill and a Dremel before. You should also check out his micro Tesla turbine, too, especially if you appreciate fine machining.

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Simple Electric Bike Conversion From 3D-Printed Parts

June 23, 2017 by Dan Maloney 27 Comments

Challenge: Perform an electric conversion on a bicycle. Problem: No significant metal working skills or equipment. Solution: 3D print everything needed to electrify the bike.

At least that’s the approach that [Tom Stanton] took to his electric bike build. Having caught the electric locomotion bug on a recent longboard build, [Tom] undertook the upgrade of a cheap “fixie,” or fixed-gear bike. His delta printer was big enough for the motor mount and weather-resistant ESC enclosure, but he needed to print the drive pulley in four quadrants that were later glued together. We can’t say we hold much faith in the zip ties that transmit all the torque through the rear wheel’s spokes, but as a proof of concept it seems sturdy enough. With a throttle from an electric scooter and a battery in a saddle bag, the bike turns in pretty decent performance — at least after a minor gearing change. And everything blends in or accents the black frame of the bike, so it’s a good-looking build to boot.

Want to catch the cheap electric personal transportation bug too? Check out this electric longboard, or this all-terrain hoverboard.

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When Life Gives You An F-15 Throttle Grip Make A Cool Joystick

March 2, 2016 by Gerrit Coetzee 21 Comments

We’re not certain where [NoPleaseDont] got an F-15 Throttle Grip, but it would certainly be a waste not to make something cool out of one. The F-15 is a twin engine air superiority fighter, and in it’s niche, it is one of the most successful ever made. We imagine this makes it a popular choice in air simulators.

Equipped with his successful scrounge [NoPleaseDont] decided to build a full HOTAS, Hands On Throttle and Stick, joystick. He started by taking apart the throttle grip. As each layer was pulled a part, we were pleased to see the reassuring infestation of quality control stamps you’d expect to find on the input of a 26million dollar machine. The pinouts were presumably taken and the handle was reassembled. After that, a lot of custom sheet metal parts, 3D prints, and clever bracketry came together to form the frame of the joystick.

Finally came the electronics. Many of the photos were too blurry to decode, but at minimum a Teensy and custom LED control board is involved. The frame got a few additional buttons and control panels added.

The resulting joystick has a great history, and more buttons than we can guess the purpose of.

Custom Controllers For Kerbal Space Program

July 3, 2014 by Brian Benchoff 17 Comments

kerbal Kerbal Space Program is already a runaway indie video game hit, and if you ask some people, they’ll tell you it is the way to learn all about orbital dynamics, how spaceships actually fly, the challenges of getting to the mün. The controls in KSP are primarily keyboard and mouse, something that really breaks the immersion for a space flight simulator. We’ve seen a few before, but now custom controllers well suited for a Kerbal command pod can be made at home, with all the blinkey LEDs, gauges, and buttons you could want.

[Freshmeat] over on the KSP forums began his space adventures with a keyboard but found the fine control lacking. An old Logitech Dual Shock controller offered better control, but this gamepad doesn’t come with a throttle, and USB throttles for flight sims are expensive. He found a neat plugin for KSP made for interfacing an Arduino, and with a few modifications, turned his controller into a control panel, complete with sliders, pots, gauges, and all the other goodies a proper command pod should have.

[Freshmeat]’s work is not the only custom Kerbal controller. There’s a whole thread of them, with implementations that would look great in everything from a modern spaceplane to kerbalkind’s first steps into the milky abyss of space. There’s even one over on the Hackaday projects site, ready to fly Bill, Bob, and Jeb to the mün or a fiery explosion. Either one works.

Thanks [drago] for the tip.

Keep Tabs On Your Car Without OBD-II

March 16, 2010 by Jakob Griffith 37 Comments

[Steve] let us know about his MultiDisplay car monitoring system. Unlike traditional systems that rely on interfacing with the OBD-II protocol and existing car computer, the MultiDisplay uses an Arduino and custom shield with a combination of sensors; including temperatures, pressures, throttle, Boost, and etc. The data collected can then be displayed on a 20×4 LCD or streamed to a PC with visualization and event recording.

It’s nice to see half a years worth of work finally be complete and presented in such a clean and professional manner, keep up the good work [Steve]