Celebrating The Olympics With Flaming Windmills

February 9, 2018 by Tom Nardi 5 Comments

Like many of us, [Gustav Evertsson] was looking for an excuse to set stuff on fire and spin it around really fast to see what would happen. Luckily for him (and us) the Winter Olympics have started, which ended up being the perfect guise for this particular experiment. With some motors from eBay and some flaming steel wool, he created a particularly terrifying version of the Olympic’s iconic linked rings logo. Even if you won’t be tuning in for the ~~commercials~~ Winter Games, you should at least set aside 6 minutes to watch this build video.

The beginning of the build starts with some mounting brackets getting designed in Fusion 360, and you would be forgiven if you thought some 3D printed parts were coming up next. But [Gustav] actually loads the design up on a Carbide 3D CNC and cuts them out of wood.

A metal hub is attached to each bracket, and then the two pieces are screwed onto a length of thin wood. This assembly is then mounted up to the spindle of a geared motor rated for 300 RPM. The end result looks like a large flat airplane propeller. Five of these “propellers” are created, one for each ring of the Olympic’s logo.

Once the sun sets, [Gustav] takes his collection of spinners outside and lines them up like windmills. At the end of each arm is a small ball of fine-grade steel wool, which will emit sparks for a few seconds when lighted. All you’ve got to do is get the 10 pieces of steel wool alight at the same time, spin up the motors, and let persistence of vision do the rest. If you can manage the timing, you’ll be treated with a spinning and sparking version of the Olympic rings that wouldn’t look out of place in a new Mad Max movie.

Generally speaking, we don’t see much overlap between the hacker community and the Olympics. You’d have to go all the way back to 2012 to find another project celebrating this particular display of athleticism. We would strongly caution you not to combine both of these Olympic hacks at the same time, incidentally.

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Robotic Table Saw Automates Finger Joints

January 13, 2018 by Dan Maloney 19 Comments

We’ve all seen finger joints or box joints, those interlocking puzzle pieces that make laser-cut plywood enclosures such a fixture for DIY projects. But laser cutters make finger joints look much easier to fabricate than they are with traditional woodworking tools, which often lead to disappointing results.

But this finger joint cutting robot is no traditional woodworking tool, and [timschefter] put a lot of work into building the rig. We have to admit that when we first saw the video below, the thought of having a table saw in our shop that could be turned on with a button on a phone gave us pause. But on closer analysis, it looks like safety was a major concern with this build. With a prominent e-stop and an interlock switch, the small table saw that forms the foundation of the robot should be safe enough. On the table top is a sled with a linear slide that moves the workpiece perpendicular to the blade, and the sled moves back and forth over the blade with pneumatic cylinders. The joint is set up with a custom app which calculates the pin width and spacing, which can be evenly distributed across the panel, or, for a bit of geeky fun, controlled to make a joint that encodes a message in Morse.

A lot of work went into this, and while it’s not the first robotic finger joint cutter we’ve seen, it’s pretty impressive. Now if it could only automate dovetails.

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Pi Handheld With A Mindblowing Enclosure

November 2, 2017 by Lewin Day 14 Comments

The Raspberry Pi is possibly the world’s most popular emulation platform these days. While it was never intended to serve this purpose, the fact remains that a small, compact computer with flexible I/O is ideally suited to it. We’ve featured a multitude of builds over the years using a Pi in a mobile form factor to take games on the go. [Michael]’s build, however, offers a lot more than a few Nintendo ROMs and some buttons from eBay. It’s a tour de force in enclosure design.

The build starts with the electronics. In 2017 it’s no longer necessary to cobble together five different accessory boards to handle the controls, battery charging, and display. Boards like Kite’s Super All In One exist, handling everything necessary for a handheld game console. With this as a starting point, he then set out to recreate Nintendo’s classic Game Boy, with a few tweaks to form and function.

It’s a textbook example of smart planning, design, and execution. We are taken through the process of creating the initial CAD drawings, then combining 3D printed parts with wood and carbon fibre for a look that is more akin to a high-end piece of hi-fi gear than anything related to gaming. The attention to detail is superb and the write-up makes it look easy, while [Michael] shares tips on how to safely cut carbon fibre to make your own buttons.

The final results are stunning, and it’s a great example of why a fine piece of wood is always a classy way to go for an enclosure. For another great example, try this walnut keyboard, or check out the roots of the Raspberry Pi Game Boy movement.

Engineering And Artistry Meet An Untimely End At Burning Man

October 6, 2017 by Dan Maloney 38 Comments

Burning Man is so many different things to so many people, that it defies neat description. For those who attend, it always seems to be a life-changing experience, for good or for ill. The story of one man’s Burning Man exhibition is a lesson in true craftsmanship and mind-boggling engineering, as well as how some events can bring out the worst in people.

For [Malcolm Tibbets], aka [the tahoeturner], Burning Man 2017 was a new experience. Having visited last year’s desert saturnalia to see his son [Andy]’s exhibition, the studio artist decided to undertake a massive display in his medium of choice — segmented woodturning. Not content to display a bamboo Death Star, [Malcolm] went big– really big. He cut and glued 31,000 pieces of redwood into rings of various shapes and sizes and built sculptures of amazing complexity, including endless tubes that knot and loop around and back into each other. Many of the sculpture were suspended from a huge steel tripod fabricated by [Andy], forming an interactive mobile and kinetic sculpture.

Alas, Burning Man isn’t all mellowness in the desert. People tried to climb the tripod, and overnight someone destroyed some of the bigger elements of the installation. [Malcolm] made a follow-up video about the vandalism, but you’ll want to watch the build video below first to truly appreciate the scale of the piece and the loss. Here’s hoping that [Malcolm]’s next display is treated with a little more respect, like this interactive oasis from BM 2016 apparently was.

Thanks to [Keith Olson] for the tip.

Hand-Carving Geometric Art

September 29, 2017 by John Baichtal 5 Comments

[Scott Cramer] is a retired professional woodworker who specializes in geometric art made from beautifully joined wood. In this project he’s carving four interlocked cloverleaf rings from a block of basswood. First he made a series of cuts to turn the block into a cuboctahedron, a geometric solid comprising six squares and eight triangles. Then he drew on the basic lines of the rings on the wood and went to work with a chisel, smoothing and separating the rings and carving out the interior. You can see more shots of the project on his Facebook post, which is included after the break.

To see more of [Scott]’s projects you can follow his Twitter feed. Our favorites include this 70″ pentagonal icosatetrahedron built out of hemlock that [Scott] says is the “largest in Coös County, NH” — what, there are others? He also made a magogany representation of a Hamiltonian circuit of a dodecahedron’s vertices.

We love math art on Hackaday — see our interview with Francisco do Comité we ran earlier this year.

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A Fix For The Lightweight Machine Tool Shakes

September 16, 2017 by Dan Maloney 12 Comments

No matter what material you work with, the general rule is that with machine tools, the heavier, the better. Some people can’t afford or don’t want big tools, though, even with their natural tendency to reduce vibrations. That doesn’t mean something can’t be done to help the little tools, like reducing vibration in a contractor-grade table saw.

This one might seem a little outside the usual confines of the hackosphere, but nobody can doubt [Matthias Wandel]’s hacker chops and he really shows off his problem-solving skills with this one. His well-worn contractor-style table saw has had more than a few special modifications over the years, some of which left it with a shimmy sufficient to vibrate workpieces right off the table. He fashioned a friction damper for the saw’s motor from wood, complete with ball and socket joints to allow full movement of the blade height and angle. That didn’t quite do the trick, but his incremental approach finally found the right combination of factors, and the video below shows a saw now stable enough to balance a nickel.

If the name seems familiar but you just can’t place the hacks, check out [Matthias]’s recent wooden domino extruder, his shortcuts to tapping wood, or of course his classic wood gears layout software.

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Wooden Word Wristwatch Wows Woomies

August 25, 2017 by Elliot Williams 25 Comments

[HakuG] wanted to make a watch for his roommates, and had a design project due. He killed two birds with one stone, and then some. The result is a classic word clock, but with a refined all-wood look that’s also small enough to wear on your wrist.

Nothing good ever comes out right the first time, and the log of [HakuG]’s different versions is full of different attempts, all of them just fine in their own right, but none of them “perfect”. Kudos to [HakuG] for sticking with it and refining the project far past the initial prototype stage to something that really looks like a finished product.

Of course we’ve covered word clocks before. Heck, we’ve even seen a beautiful wooden one. But we’re pretty sure that this is the first wooden word-clock watch we’ve ever written up, and it’s surely one of the nicest.

Thanks [Paul Hein] for the link!