A Solar Frame From Scratch

“From scratch” is a bit of a murky expression. How scratchy does it get? Are you just baking your bread yourself or are you growing your own wheat? Rolling your own solar installation probably doesn’t involve manufacturing your own photovoltaic cells. But when it comes to making the frame to hold your panels, why not machine your own brackets and harvest the wood from trees nearby?. That’s what [Kris Harbour] did with his over-engineered 8.4kW solar stand.

He already had a wind turbine and a few solar panels elsewhere on the property, but [Kris] wanted a bit more power. At the start of the video, [Kris] makes an offhand comment that he wants this to last 30-40 years at a minimum. Everything from the focus on the concrete footings to the oversized brackets and beams reflects that. The brackets were cut on his plasma CNC and the wood was cut to rough dimensions using a sawmill on his property. He admits that the sapwood will rot away a bit after 20ish years, but since the core of the posts is heartwood, structurally they’ll last a long time. After planing down to the right size, cutting hole and grooves was a bit of an involved procedure. The structure is quite tall once erected and we loved watching it come together. The most impressive thing here is that this structure was put together by just a single person. All the rafters were cut and hand-chiseled to the right sizes and hoisted into place. The panels ultimately weren’t delivered on time and he had to switch to using new panels rather than the used panels he was expecting.

Previously, [Kris] had shown off his impressive hydroelectric setup. We’re looking forward to seeing the new solar array power all the projects [Kris] is planning in the future. Video after the break.

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Wooden Keycaps Minus The CNC

What’s the most important part of the keycap? The average user-who-cares might tell you it’s the look and feel, but a keyboard builder would probably say the mounting style. That’s where the rubber meets the road, after all. For anyone trying to make their own keycaps, ‘the mount itself’ is definitely the correct answer. Try printing your own keycaps, and you’ll learn a lot about tolerances when it comes to getting the mount right.

Conversely, you could use a subtractive process like a wood mill to make keycaps. Sounds easy enough, right? But what about all of us who don’t have access to one? [cbosdonnat], who has no CNC, has blazed a cellulose trail, combining hand-tooled wooden keycaps with 3D-printed mounts to create fully-customized keycaps. It’s a great project with concise how-to, especially when it comes to building the jigs needed to keep the keycaps consistently sized and shaped.

It makes a whole lot of sense to start by hollowing out the bottom instead of shaping the business side first or even cutting out the key shape, since the mount is mechanically vital. Why waste time on the look and feel if the foundation isn’t there yet?

Hardwood is a must for DIY keycaps, because the walls need to be thin enough to both fit over the switch and within the matrix, and be sturdy enough not to break with use. We love the look of the varnish-transferred laser-printed logo, and only wish there was a video so we could hear the clacking.

There are all kinds of ways to put legends on DIY keycaps, like waterslide decals for instance.

A wood-and-plastic jig to make dovetail joints

3D Printed Template Makes Perfect Dovetail Joints

Dovetail joints on a piece of furniture are one of those features that make it say “master carpenter” rather than “IKEA”. Traditional hand-made dovetails require accurate measurements and even more accurate sawing and chiseling, skills that may take years to develop. A slightly less artisanal method is to use a router and a dovetail template; the router makes perfectly straight cuts while the template makes sure it goes only where it needs to go.

If you haven’t got one of those templates yet, check out [Guy Perez]’s design for an adjustable dovetail template that’s easy to produce with a 3D printer. It consists of ten separate pieces mounted on a T-rail, which enables them to slide sideways and thereby generate pins and tails of varying widths. The T-rail is mounted on a wooden body with an integrated clamp to hold the target piece, as well as an endstop to provide a reference for all measurements.

As you can see in the video embedded below, the resulting jig is easy to use and should result in near-perfect dovetails each time. [Guy] made the CAD files available as well as detailed instructions on their design, so you can easily adjust them if you need pieces with a different tail angle or want to use thicker wood.

While this jig will make cutting ordinary dovetail joints a lot easier, you can still show off your manual skills by making an impossible mallet. Want to join metal bits instead? Check out this cute little dovetail cube.

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Multiband Crystal Radio Set Pulls Out All The Stops

Most crystal radio receivers have a decidedly “field expedient” look to them. Fashioned as they often are from a few turns of wire around an oatmeal container and a safety pin scratching the surface of a razor blade, the whole assembly often does a great impersonation of a pile of trash whose appearance gives little hope of actually working. And yet work they do, usually, pulling radio signals out of thin air as if by magic.

Not all crystal sets take this slapdash approach, of course, and some, like this homebrew multiband crystal receiver, aim for a feature set and fit and finish that goes way beyond the norm. The “Husky” crystal set, as it’s called by its creator [alvenh], looks like it fell through a time warp right from the 1920s. The electronics are based on the Australian “Mystery Set” circuit, with modifications to make the receiver tunable over multiple bands. Rather than the traditional galena crystal and cat’s whisker detector, a pair of1N34A germanium diodes are used as rectifiers — one for demodulating the audio signal, and the other to drive a microammeter to indicate signal strength. A cat’s whisker is included for looks, though, mounted to the black acrylic front panel along with nice chunky knobs and homebrew rotary switches for band selection and antenna.

As nice as the details on the electronics are, it’s the case that really sells this build. Using quarter-sawn oak salvaged from old floorboards. The joinery is beautiful and the hardware is period correct; we especially appreciate the work that went into transforming a common flat washer into a nickel-plated escutcheon for the lock — because every radio needs a lock.

Congratulations to [Alvenh] for pulling off such a wonderful build, and really celebrating the craftsmanship of the early days of radio. Need some crystal radio theory before tackling your build? Check out [Greg Charvat]’s crystal radio deep dive.

Bring Precision To The Woodshop With An Electronic Router Lift

One of the knocks that woodworkers get from the metalworking crowd is that their chosen material is a bit… compliant. Measurements only need to be within a 1/16th of an inch or so, or about a millimeter, depending on which side of the Atlantic you’re on. And if you’re off a bit? No worries, that’s what sandpaper is for.

This electronic router lift is intended to close the precision gap and make woodworking a bit less subjective. [GavinL]’s build instructions are clearly aimed at woodworkers who haven’t dabbled in the world of Arduinos and stepper motors, and he does an admirable job of addressing the hesitancy this group might feel when tackling such a build. Luckily, a lot of the mechanical side of this project can be addressed with a commercially available router lift, which attaches to a table-mounted plunge router and allows fine adjustment of the cutting tool’s height from above the table.

What’s left is to add a NEMA 23 stepper to drive the router lift, plus an Arduino to control it. [GavinL] came up with some nice features, like a rapid jog control, a fine adjustment encoder, and the ability to send the tool all the way up or all the way down quickly. Another really nice touch is the contact sensor, which is a pair of magnetic probes that attach temporarily to the tool and a height gauge to indicate touch-off. Check the video below to see it all in action.

One quibble we have with [GavinL]’s setup is the amount of dust that the stepper will be subjected to. He might need to switch out to a dustproof stepper sooner rather than later. Even so, we think he did a great job bridging the gap between mechatronics and woodworking — something that [Matthias Wandel] has been doing great work on, too.

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The octagonal wooden box described in the project. On the left, outer surface of the box is shown, with "Say Friend And Come In" inscription, as well as a few draings (presumably from Lord of The Rings) and two metallic color stars that happen to serve as capacitative sensor electrodes. On the right, underside of the lid is shown, with all the electronics involved glued into CNC-machined channels.

Say Friend And Have This Box Open For You

Handcrafted gifts are special, and this one’s no exception. [John Pender] made a Tolkien-inspired box for his son and shared the details with us on Hackaday.io. This one-of-a-kind handcrafted box fulfills one role and does it perfectly – just like with the Doors of Durin, you have to say ‘friend’ in Elvish, and the box shall unlock for you.

This box, carefully engraved and with attention paid to its surface finish, stands on its own as a gift. However, with the voice recognition function, it’s a project complicated enough to cover quite a few fields at once – woodworking, electronics, and software. The electronics are laid out in CNC-machined channels, and LED strips illuminate the “Say Friend And Come In” inscriptions once the box is ready to listen. If you’re wondering how the unlocking process works, the video embedded below shows it all.

Two solenoids keep the lid locked, and in its center is a Pi Zero, the brains of the operation. With small batteries and a power-hungry board, power management is a bit intricate. Two capacitive sensors and a small power management device are always powered up. When both of the sensors are touched, a power switch module from Pololu wakes the Pi up. It, in turn, takes its sweet time, as fully-fledged Linux boards do, and lights up the LED strip once it’s listening.

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Tech In Plain Sight: Tough As Nails

When you think of machines you see around you every day, you probably think about your car, computer, or household appliances. However, the world is full of simple machines. One simple machine in particular, the inclined plane, shows up a lot. For example, think of the humble nail. If you are a woodworker or even a homeowner you probably have bags of them. They certainly are all around you if you are indoors and maybe even if you are outdoors right now. Nails have been the fastener of choice for a very long time and they are a form of a wedge which is a type of inclined plane.

What else can you say about nails? Turns out, there is a lot to know. Like other fasteners, there are nails for very specific purposes. There are even nails with two heads and — no kidding — nails with two points. Exactly what kind of nail you need depends on what you are doing and what’s important to you.

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