On the shortlist of workshop luxuries, we’d bet a lot of hackers would include an overhead crane. Having the ability to lift heavy loads safely and easily opens up a world of new projects, and puts the shop into an entirely different class of capabilities.
As with many of us, [Jornt] works in a shop with significant space constraints, so the jib crane he built had to be a custom job. Fabricated completely from steel tube, the build started with fabricating a mast to support the crane and squeezing it into a small slot in some existing shelves in the shop, which somehow didn’t catch on fire despite being welded in situ. A lot of custom parts went into the slewing gear that mounts the jib, itself a stick-built space frame that had to accommodate a pitched ceiling. A double row of tubing along the bottom of the jib allows a trolley carrying a 500 kg electric winch to run along it, providing a work envelope that looks like it covers the majority of the shop. And hats off for the safety yellow and black paint job — very industrial.
From the look of the tests in the video below, the crane is more than up to the task of lifting engines and other heavy loads in the shop. That should prove handy if [Jornt] tackles another build like his no-compromises DIY lathe again.
While gliding might be the most calm and peaceful way of moving through the air, launching a glider is a rather noisy and violent process. Although electric winches do exist, most airfields use big V8-powered machines to get their gliders airborne. [Peter Turczak] noticed that the winch operators at his airfield often had to juggle multiple communication channels while pressing buttons and moving levers, all with the deafening roar of a combustion engine right next to them. To make their life easier, he built a single communication device that combines multiple radio inputs and an analog telephone .
The main user interface is a sturdy headset that dampens engine noise significantly. This headset is connected to a cabinet that contains several modules connecting to different audio sources: an analog telephone line, an aircraft radio receiver, a PMR handheld radio, and even a music source in case the other lines are quiet. The system contains automatic switchover circuits based on a priority system, ensuring that important messages are never missed.
The electronic design is based on classic analog components like NE5532 and TL084 op amps, all mounted on small, custom-made PCBs. Audio transformers are used to avoid ground loops between the various signal sources while relays mute sources that are not prioritized. To ensure seamless compatibility with the telephone network, [Peter] used components from old desk phones, including line transformers, a DTMF keypad and even a mechanical ringer. His blog post is full of details that will be of interest to anyone working with op amps and audio, such as how to stabilize an amplifier that has significant wiring capacitance on its input.
At heart this whole project is “just” an audio mixer, although optimized for a very specific purpose. But designing even a simple mixer is by no means an easy task, as we reported a few years back. If you’re more into winches, you’ll be delighted to find that smaller ones can also be used for sledding and even wakeboarding.
For a satisfying Youtube watching session there is noting like some quality machine shop work, and that’s exactly what [Made In Poland] supply with their conversion of a small 12V winch to power from a chainsaw. The finished product contains not much more than the gearbox and shaft components from the original, but the mesmerising sight of rusty steel stock being transformed into dimension-perfect components which come together to form an entirely new assembly is as always a draw.
The conversion starts with the removal and disassembly of the motor to reveal its shaft and the locking mechanism for the drum. The shaft is then turned down and a collar manufactured to couple it to the drive spline on a chainsaw. We’re pleased to see that the chainsaw isn’t modified in this build, instead the blade is simply unscrewed and the winch attached in a reversible process. Finally, the original drum is deemed too small for the application, so a new drum is fabricated. We see the result on a Polish farm, happily participating in some forestry work and even pulling their pickup truck when it became stuck.
There are a lot of things in our everyday life that are holdovers from an earlier time that we continue to use simply because of inertia even if they don’t make a lot of sense in modern times. Examples include a 60 Hz power grid, the spacing between railroad tracks, and of course the self-contained attic ladder which is made to fit in between standard spaced ceiling joists. It’s not wide enough to get big or heavy stuff into an attic, and building standards won’t change just for this one inconvenience, so if you want to turn that space into something more usable you’re going to need to build a custom elevator.
This attic elevator comes to us from [Brian] who recently moved into a home with about half the square footage as his previous home, but still needed to hold all of his stuff. That means clever ways of using the available space. For the elevator he constructed a platform out of 2x lumber held together with bolts and steel supports. The carriage runs up and down on a track made out 1 5/8″ super strut and is hoisted by a winch motor rated for 550 pounds, which is more than enough to hoist up most household items including a large toolbox.
Vertical storage is often underused in the garage or workshop as it can be tricky to get bulky objects off the floor safely. So we stick a few shelves on the wall, put boxes of screws and components on them, and call it a day. Meanwhile, you end up playing a game of horizontal Tetris with all the big stuff on the ground.
Before he started the actual build, [Chris] knocked together a rough facsimile of his garage in SolidWorks and started experimenting with the layout and mechanism that the hoist would ultimately use. While we’ve all felt the desire to run into a project full-speed, this more methodical approach can definitely save you time and money when working on a complex project. Redesigning a component in CAD to try it a different way will always be faster and easier than having to do it for real.
We’ve become accustomed to seeing projects include sensors, microcontrollers, and 3D printed components as a matter of course, but [Chris] kept this build relatively low-tech. Not that we blame him when heavy overhead loads are involved. Even still, he did have to make a few tweaks in the name of safety: his original ratcheting winch could freewheel under load, so he swapped it out for a worm gear version that he operates with an electric drill.
Ever since he looked into them as a way to water and care for his plants, [Tom] has been fascinated with cable robots. These high-flying gadgets can move in three dimensions over huge areas, provided you’ve got the ability to string up the aforementioned cables. But despite their flexibility, there hasn’t been a whole lot of hobbyist level development with these unique systems.
So what can you do with a cable robot? In the video after the break, [Tom] shows one of his creations dutifully transporting beer cans across the room and stacking them into a pyramid. Admittedly this isn’t a particularly useful capability (unless you run a bar, perhaps), but it does show the speed and dexterity of the system even when crossing large distances. If you’ve ever wanted to play the home edition of “Automate the Freight”, this one’s for you.
The system uses a trio of 36 volt stepper motors powered by a homebrew SLA7078 driver that [Tom] designed himself. Each stepper turns a geared-down spindle to which a strong cable is attached. With some clever routing around the workspace, careful orchestration of these small winches can be used to move the point where all the cables meet in 3D space. All that’s left is mounting your gadget of choice to this central point, and away you go.
If necessity is the mother of invention, then laziness is probably its father. Or at least a close uncle. Who hasn’t thought, “There has to be a better way to do this, one that doesn’t involve me burning precious calories”?
Motivational laziness seems to increase with potential energy, as anyone who needs to haul groceries up four flights of stairs will tell you. This appears to be where this balcony-mounted drill-powered crane came from. Starting with a surplus right-angle gearbox and drum, [geniusz K] fabricated the rest of the crane from steel plate and tubing. We like the quality of fabrication and the tip on making slip couplings from bits of square tubing. The finished product got a nice coat of brown paint to match the balcony railing; keeping the neighbors happy is always important. He tested the crane with a 20-kg weight before installing it on the balcony and put it to work hauling groceries up three stories. Check out the build and the test in the video below.