Project Egress: [Fran] Makes A Latch

July 4, 2019 by Dan Maloney 11 Comments

[Fran Blanche] is on the team of elite hackers that has been offered a chance to contribute to [Adam Savage]’s Project Egress, a celebration of the engineering that got humanity to the Moon 50 years ago this month. By the luck of the draw, she landed a great assignment: building a replica of one of the fifteen latches that kept the Apollo Command Module hatch dogged down against the vacuum of space, and she’s doing a great job documenting her build with some interesting videos.

The first video below is mostly her talking through her design process, materials choices, and ideas about fabricating the somewhat intricate pieces of the latch. All 44 makers involved in the project get to choose what materials and methods they’ll use to make their parts, and [Fran] decided to use wood. Her first inclination was to use oak and brass, a nice combination with an 80s vibe, but in the second video, which covers more of the initial fabrication, she explains her switch to walnut. Unfortunately, the only CNC option she has is a Shaper Origin, which presents some difficulties; the handheld tool requires some complicated fixturing to safely machine the small parts needed, and its inability to read STL files means that [Fran] is stuck with a complicated software toolchain to drive the tool.

There are more videos to come as [Fran] gets further into the build, and we’re looking forward to seeing how her part and the rest of the makers’ builds come out.

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Tiny Wooden Laptop Packs Raspberry Pi

May 28, 2019 by Lewin Day 8 Comments

Building a handheld Raspberry Pi rig is practically a hacker rite of passage these days. Off-the-shelf parts keep getting better, and we’re now starting to see affordable compact LCD screens with decent resolution become common. [MakeFailRepeat] got his hands on a HyperPixel screen, and decided to whip up a neat project with it.

The result is a charming little laptop, packing a 4″ screen with 800×480 resolution. Input is via multi-touch, as well as an integrated keyboard. The frame of the laptop is wooden, with a 3D printer supplying parts for the hinge mechanism. To round out the aesthetics, the top of the device was given a decorative copper inlay. Power management is via a UPS hat, which allows the device to switch seamlessly between battery and mains power.

A project like this is a great way to learn a wide range of valuable skills. It involves woodworking and 3D design, as well as the basic configuration of a single board computer. They come in all shapes and sizes, like this tiny RetroPie handheld, or this slick laptop build. Video after the break.

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JigFab Makes Woodworking Easier

April 22, 2019 by Lewin Day 20 Comments

Woodworking is an age-old craft that requires creativity and skill to get the best results. Experienced hands get the best results, while the new builder may struggle to confidently produce even basic pieces. JigFab is here to level the playing field somewhat.

Much of the skill in woodworking comes with mastering the various joints and techniques required to hold a piece together. Cutting these joints often requires specialized tools and equipment – ideally, some sort of jig. These jigs can be difficult to build in themselves, and that’s where JigFab shines.

The workflow is straightforward and quite modern. A piece is designed in Autodesk Fusion 360. Various joints can then be defined in the model between individual parts. JigFab then generates a series of laser cut constraints that can be used with power tools to easily and accurately cut the necessary parts to build the final piece.

It’s an impressive technology which could rapidly speed the workflow of anyone experimenting with woodwork and design. There’s even smart choices, like having a toolkit of standard predefined elements that reduce laser cutting time when producing new constraints. If you’re eager to get stuck in to woodwork, but don’t know where to start, don’t worry – we’ve got a primer for that. Video after the break.

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Building An Artisanal Tape Measure

March 27, 2019 by Tom Nardi 13 Comments

Some tools are so common, so basic, that we take them for granted. A perfect example is the lowly tape measure. We’ve probably all got a few of these kicking around the lab, and they aren’t exactly the kind of thing you give a lot of thought to when you’re using them. But while most of us might not give our tape measure a second thought, [Ariel Yahni] decided to create an absolutely gorgeous new enclosure for his. Because if you’re going to measure something, why not look good doing it?

A CNC router is used to carve the body of the new tape measure out of a solid block of wood and cut a top plate out of clear acrylic. [Ariel] then used an angle grinder to cut off a small section of steel rod which he secured into a carved pocket in the base using epoxy. Finally, the internals of a commercial tape measure were inserted into this new enclosure, and the acrylic top was screwed down into place.

[Ariel] has made the DXF files for this project public for anyone else who wants to carve out their own heirloom tape measure, though it seems likely the designs will need some tweaking depending on the make and model of donor tape measure. While this might not be the most technically impressive project to run on Hackaday, it’s still a fantastic example of the sort of bespoke designs that are made possible with modern manufacturing methods.

This design reminds us of a similar project to turn a basic Honda key fob into a true conversation piece with the addition of some CNC’d hardwood and aluminum.

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Downdraft Table Inhales Dust, Not Cash

March 14, 2019 by Tom Nardi 15 Comments

We always look forward to the builds [MakerMan] sends in, and it’s not just because we dig his choices in royalty free music (though it helps). He always manages to put together his projects with a minimum of fuss, and perhaps more importantly, a minimum of funds. His builds use salvaged components, easily sourced materials, and common tools. Watching him work invariably makes us realize that we tend to overthink our own projects.

In his latest video, [MakerMan] was tasked with building a downdraft table for a local factory that makes jewelry boxes. By sucking air through a series of holes in the table’s surface, sawdust created while the workers are building the boxes will automatically be removed from the workspace. Even if you aren’t in the jewelry box making business, any task which produces fine particles (such as sanding) could benefit from such a setup. You probably won’t need a downdraft table quite as large as the one he builds, but the principles will be the same if you get inspired to build a somewhat smaller version.

The build starts with sheets of MDF, which get cut, glued, and screwed together to make the basic tabletop shape. To this, [MakerMan] attaches a welded steel frame which will give it the strength MDF itself lacks. With careful measurement, lines are plotted across the top of the MDF sheet and all the holes are drilled with a simple hand drill; no fancy CNC here.

With the table doing its best colander impression, [MakerMan] adds an air box to the bottom which is similarly made of thin MDF sheets. All of the joints are sealed up with caulk, because at this point you want things to be as air tight as possible. A large blower is attached to the bottom, which gets piped to a dust collection system that’s made of a garbage can and…you guessed it, more MDF.

Watching [MakerMan] turn what’s often literal trash into a functional build never gets old. We’ve seen him create everything from a gorgeous origami chandelier to a very impressive diode laser cutter using little more than scrap parts and hand tools, and we can’t wait to see what he comes up with next.

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Become The Next Fabergé With A Rose Engine Lathe

March 13, 2019 by Bryan Cockfield 12 Comments

The basics of a skill may take a long time to master, but there is always something else to learn about regardless of the craft. Building a piece of fine furniture out of hardwood or being able to weld together a bicycle from scratch are all impressive feats, but there are fine details that you’ll only learn about once you get to this level of craftsmanship. One such tool that will help with these intricacies is known as the rose engine lathe.

This tool is based on an average lathe, typically used for creating round things out of stock which is not round. A rose engine lathe has a set of cams on it as well which allow the lathe to create intricate patterns in the material it’s working with, such as flower type patterns or intricate spirals. One of the most famous implementations of this method was on the Fabergé eggs. While this might make it sound overly complex, this how-to actually shows you how to build your own rose engine lathe out of a piece of MDF and a large number of miscellaneous pieces of hardware.

We recently featured another build which performs a similar function called engine turning. While similar, this is the method responsible for creating overlapping spirals on a piece of metal. Either way, both projects are sure to spice up your metal or woodworking endeavors.

Thanks to [PWalsh] for the tip!

Art Deco Control Panel Looks Out Of Metropolis

February 23, 2019 by Dan Maloney 9 Comments

Bakelite, hammertone gray finish, big chunky toggle switches, jeweled pilot lights – these are a few of [Wesley Treat]’s favorite retro electronics things. And he’ll get no argument from us, as old gear is one of our many weak spots. So when he was tasked by a friend to come up with some chaser lights for an Art Deco-themed bar, [Wesley] jumped at the chance to go overboard with this retro-style control panel.

Granted, the video below pays short shrift to the electronics side of this build in favor of concentrating on the woodworking and metalworking aspects of making the control panel. We’re OK with that, too, as we picked up a ton of design tips along the way. The control panel is all custom, with a chassis bent from sheet aluminum. The sides of the console are laminated walnut and brushed aluminum, which looks very chic. We really like the recessed labels for the switches and indicators on the front panel, although we’d have preferred them to be backlighted. And that bent aluminum badge really lends a Chrysler Building flair that ties the whole project together.

All in all, a really nice job, and another in a long string of retro cool projects from [Wesley]. We recently featured his cloning of vintage knobs for an old Philo tube tester, and we’ll be looking for more great projects from him in the future.

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