Testing A Laser Cut Wrench VS A Forged Wrench

August 13, 2022 by Al Williams 29 Comments

It is easy to not think much about common tools like screwdrivers and wrenches. But not for [Torque Test Channel]. The channel does a lot of testing of tools and in the video, below, they test a new wrench that is, oddly enough, laser cut instead of forged like the usual wrench.

You would expect a machined wrench to be weaker than a forged wrench. We were impressed, though, that there is so much difference between wrenches when you start making measurements.

Speaking of measurements, we would like to see more details of the test setups shown both in the video and in some of the video clips included. We did enjoy seeing the examination of the internal grain structure of both wrenches.

Be forewarned. Watching this video is likely going to send you to the computer to buy some new wrenches, especially if you don’t have 30/60 head wrenches.

The real question is why laser cut a wrench? It doesn’t seem like it is actually better than the forged variant. It is more expensive, but the setup costs for forging are higher. Particularly for a tool made in the United States, forging is both expensive and it is difficult to find time on the limited number of large-scale forges left in the country.

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Resulting tweezer assembly, with a 3D printed replacement case for both of the probes

Hackaday Prize 2022: Glue-Hindered Smart Tweezer Repair Involves A Rebuild

May 23, 2022 by Arya Voronova 1 Comment

[Dan Julio] owns a pair of Miniware multimeter tweezers, a nifty helper tool for all things SMD exploration. One day, he found them broken – unable to recognize any component between the two probes. He thought it could be a broken connection problem, and decided to take them apart. Presence of some screws on their case fooled him – in the end, it turned out that the case was glued together, and could only be opened destructively. For an entry in the “Reuse, Recycle, Revamp” round of 2022 Hackaday Prize, he tells us how he brought these tweezers back from the dead.

During the disassembly, he broke a custom flexible PCB, which wasn’t reassuring either. However, that was no reason to give up – he reverse-engineered the connections and the charging circuitry, then assembled parts of the broken tweezers together using a small generic protoboard as a base. Indeed, it was likely a broken connection between probes, because the reassembled tweezers worked!

Of course, having exposed PCBs wouldn’t do, and from the very start, assembling these tweezers back together was not an option. Instead, he developed a replacement case in OpenSCAD, bringing the tweezers back to life as his trusty tool – and still leaving repairability on the table. If you’re interested in the details, he goes more into how these tweezers are designed when it comes to charging and connectivity, and we recommend that you give his write-up a read!

We’ve been seeing smart tweezers around for over a decade now, from reviews and hacks of commercially made ones, to DIY chopstick-based and PCB-based ones. If you already own a pair of tweezers you’ve grown attached to, you can neatly retrofit them with a capacitance sensing function!

Flexible Grip For Hammer Made With 3D Printing Pen

May 19, 2022 by Lewin Day 17 Comments

When it comes to putting a flexible grip on a tool, you might reach for a self-fusing silicone tape or other similar product. However, [Potent Printables] has discovered you can easily create a flexible grip using a 3D-printing pen and some flex filament.

In this case, a hammer first gets a layer of blue painters tape wrapped around its wooden handle. This serves as a base layer to promote good adhesion. A simple paper template was then printed as a guide for creating the graphics on the flexible grip. Flexible filament was fed through the 3D pen, with the red and black details of the graphics printed first. Then, white flex filament was used to make the rest of the flexible grip. A wood burning tool was then used to smooth out the first layer of flex filament, before a second layer was added on top.

The result is a flexible white grip on the hammer which is stuck fast, likely due to shrinkage as the plastic cooled after printing. We’ve seen some other creative grips made with 3D printing before, too. Video after the break.

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SMT Part Counter Aims To Ease Taking Inventory

April 20, 2022 by Donald Papp 16 Comments

[Nick Poole] has an interesting idea for a new tool, one that has the simple goal of making accurate part counts of SMT reels as easy as pulling tape through a device. That device is the BeanCounter, an upcoming small handheld unit of his own design that counts parts as quickly as one can pull tape through a slot. The device is powered by a CR2032 cell and and works with 8 mm wide tapes up to 2 mm in height, which [Nick] says covers most 0805 or smaller sized parts, as well as things like SOT-23 transistors.

Why would one want to make such a task easier? Two compelling reasons for such a tool include: taking inventory of parts on partial reels or cut tape, and creating segments that contain a known number of parts.

The first is handy for obvious reasons, and the second is useful for things like creating kits. In fact, the usefulness of this tool for creating tape segments of fixed length is perhaps not obvious to anyone who hasn’t done it by hand. Sure, one can measure SMT tape with a ruler or a reference mark to yield a segment containing a fixed number of parts, but that involves a lot of handling and doesn’t scale up very well. In fact, the hassle of cutting tape segments accurately and repeatedly is a common pain point, so making the job easier has value.

If you looked at the photos and suspected that the big, 7-segment numeric display is done with clever PCB fabrication options (making segments by shining LEDs through PCB layers, a trick we always like to see) you’re not alone. After all, [Nick] has a lot of experience in getting clever with board fabrication, and eagle-eyed readers may even suspect that the reset and setup buttons on the edge of the tool are created by using flex PCB segments as switches. Want the nitty-gritty details? Visit the GitHub repository for the project and see it all for yourself at the CAD level.

Confessions Of A Crimpoholic

April 4, 2022 by Dan Maloney 80 Comments

Hi, my name is Dan and I’m a crimpoholic.

Honestly, I didn’t know I was a serial abuser of crimping tools until this weekend. I’ve been working on a small solar power system, and on Saturday I found myself struggling to get the BMS installed on the battery. I bought a Bluetooth dongle to connect the BMS to a smartphone app for checking the individual cells of the battery. I assumed it would just plug right into the UART port on the BMS, but alas — different connectors. So off I went to my bench, looking for a sensible way to make the connection.

My first thought was to simply log the connector off the dongle and solder the leads to the traces on the PCB right below the UART port. But then I saw that the pins in the port looked like 0.1″ pitch, so I rummaged through my stash to see what I could find. To my surprise, I had not only a kit of 0.1″ female crimps and housings, but I also had the crimping tool for them! I had no memory of making the purchase, but I thanked my lucky stars that I did, and got on with the job.

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Keep The Sparks Away With A Plasma Cutting Table

December 5, 2021 by Bryan Cockfield 8 Comments

For one-off projects or prototypes it’s not uncommon for us to make do with whatever workspace we have on hand. Using a deck railing as an impromptu sawhorse, for example, is one that might be familiar to anyone who owns a circular saw, but [Daniel] has a slightly different situation. He had been setting up metal workpieces on random chunks of brick in order to use his plasma cutter, but just like the home handyman who gets tired of nicking their deck with a saw, he decided to come up with a more permanent solution and built a custom plasma cutting table.

Plasma cutting has a tendency to throw up a lot of sparks, so most commercial offerings for plasma cutting tables include a water bath to catch all of the debris from the cutting process. [Daniel] builds his table over a metal tub to hold some water for this purpose. The table itself is built out of aluminum and designed to be built without welding even though most people with plasma cutters probably have welders as well. The frame is designed to be exceptionally strong and includes curved slats which add to the strength of the table. The table is also designed to be portable, so the curved slats stay in place when the table is moved.

While this might seem like an average metal table at first glance, the table is actually being designed with a homemade CNC machine in mind which [Daniel] is working on. The CNC plasma cutter needs a sturdy, flat surface and can’t be set up on bricks in the driveway, so this table suits both [Daniel]’s immediate needs to not shower himself in sparks every time he cuts something and also his future CNC machine’s need for a sturdy, flat workspace. We look forward to seeing that build being completed but in the meantime take a look at this motorized plasma cutter which has the beginnings of a CNC machine if in one direction only.

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Improving A Mini-Lathe With A Few Clever Hacks

November 13, 2021 by Dan Maloney 19 Comments

Like many budget machinists, the delightfully optimistically named [We Can Do That Better] had trouble with some of the finer controls on his import mini-lathe. But rather than suffer through it, he chose to rectify the machine’s shortcomings and in the process, teach everyone a bunch of great tips.

[We Can Do That Better]’s lathe retrofit focused on the carriage handwheel, which appears to lack proper bearings and wobbles around in a most imprecise manner. On top of that, the gearing of the drive made for an unsatisfying 19 mm of carriage travel per revolution of the handwheel. A single gear change made that an even 20 mm per rev, which when coupled with a calibrated and indexed handwheel ring greatly simplifies carriage travel measurements.

While the end result of the build is pretty great in its own right, for our money the best part of the video is its rich collection of machinist’s tips. The use of a wooden dowel and a printed paper template to stand in for a proper dividing head was brilliant, as was using the tailstock of the lathe to drive an engraving tool to cut the index lines. We’ve seen the use of a Dremel tool mounted to the toolpost to stand in for a milling machine before, but it’s always nice to see that trick used. And the mechanism for locking the dial to the handwheel was really clever, too.

Considering a mini-lathe? As encouraging as [We Can Do That Better]’s experience may be, it might be wise to take a deep dive into the pros and cons of such a machine.

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