Building A Heavy-Duty Log Splitter, One Piece At A Time

November 3, 2021 by Tom Nardi 9 Comments

With temperatures dropping in the Northern Hemisphere, this is the time of year when many people start processing firewood for the coming winter months. For the city folks, that means chopping a tree into logs, and then splitting those logs into something small enough to fit in your wood stove. You can do it all with hand tools, but if you’ve got big enough logs, a powered splitter is a worthy investment.

Unless of course you’re like [Workshop From Scratch], in which case you can craft a powerful splitter from random bits of steel you’ve got laying around your impeccably outfitted shop. Given the incredible forces some parts of the splitter will be exposed to, he really takes his time on this build to make sure everything is bulked up. Add in his legendary attention to detail, and you’ll be watching this one for awhile. Not that we’re complaining.

Early on it seemed like [Workshop From Scratch] was putting together a fairly simple log splitter, which in the most basic form is nothing more complex than a hydraulic cylinder pushing a log against a triangular piece of metal. But then he starts layering on the special features, such as the small hydraulic cylinder that can raise and lower the splitter’s fearsome looking blade.

There’s also the ladder-like feeder mechanism, which prevents the user from having to lift the log onto the machine manually; just stop the log between the rungs, and let the hydraulics raise the ramp and send the log rolling towards the machine’s hungry maw.

In short, this splitter may be a DIY project, but it’s just as strong and well built as anything on the commercial market. In fact, it’s probably an improvement over what you’d be able to find a the big box retailer. Which shouldn’t come as surprise if you’ve seen some of his previous work.

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Machining Wood Inlays, No CNC Required

October 17, 2021 by Dan Maloney 13 Comments

It’s almost hard to remember a time when the obvious answer to most questions about manufacturing wasn’t “Throw it on the CNC.” CNC machines have become so entrenched that the acronym has become a verb; few people would misunderstand a statement like “Let’s just CNC that.”

But before CNC machines became so ubiquitous, there were plenty of clever tricks for cutting material in a controlled fashion, as [Pask] shows us with this tool to machine wood for inlays. The tool is called a parser (or passer) drill, and is designed for use in conjunction with a steel template. [Pask]’s version seems pretty easy to make; a pair of mild steel bars are forged flat into spade shapes before having a cutting surface ground into them. The two halves of the drill are welded together and ground down to fit in the chuck of a hand drill, a modern nod to the fact that few people will want to use the traditional bow and breastplate that drove the original parser drills.

In use, a steel template that determines the shape of the inlay is affixed to the workpiece. The cutting edges of the bits are plunged into the template cutout to machine out the wood; the overhangs of the bits act as depth stop and guide. It only takes a few seconds to make a neat, CNC-free inlay. The video below shows the tool being made and in action.

It’s nice to see what can be accomplished without the need for fancy CNC machines. Not that we have anything against them, of course, but when the same results can be had with some scraps of steel and a little ingenuity, it’s pretty impressive. Looking for something between manual tools and CNC for woodworking? The pantorouter might be just your speed.

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It’s A Hack: Air Scrubber Controlled Using The Room Lighting

October 16, 2021 by Dave Rowntree 8 Comments

Some products just seem to be designed to be annoying. [hardmar] discovered the air filtration system installed in his son’s basement woodshop was orientated for the best airflow, but rather poorly positioned to actually turning the thing on and off. For some reason the unit has its single line-of-sight IR receiver on one side, which when mounted in some positions, forces the user to be the completely wrong position to use the supplied remote.

We find it a little unhelpful sometimes that devices specifically designed to be mounted with varying orientations don’t come fitted with IR receivers in different locations to ensure good controllability. It would get annoying really fast to have to contort oneself into some specific position just to turn something on, and some people just might not bother at all.

Proper control of dust is paramount for continued good health, and essential in any workspace or shared area. When you work wood, it produces a lot of dust. It cannot be avoided and gets into everything, your lungs included. PPE is not enough. Even in your own shop you still really should manage dust production as best you can. Options are varied from centralised extraction, per machine solutions, and often augmented with air scrubbers mounted on the ceiling to grab those fine particulates.

Instead of solving the IR placement issue, [hardmar] wanted to have the unit tied to the lighting system so that it would power on as soon as someone turned on the appropriate light and would then stay on for a fixed amount of time after the user left in order to continue scrubbing the air some more. His simple hack was to first record and analyse the IR protocol used by the remote, and program an Arduino to be able to send it on/off commands. Next, he hooked up a phototransistor aimed at the light, in order to provide the necessary ‘user present’ trigger to tell the Arduino when to activate the scrubber. Super simple and effective. We love this non-invasive approach of adapting off-the-shelf equipment to our specific requirements, without even showing it a screwdriver.

As [hardmar] admits, the hack is not elegantly implemented, it’s just enough to make it work, and that’s just fine, sometimes you just have a job to do and no more.

How To Get Good With Wood

September 6, 2021 by Tom Nardi 6 Comments

It’s perhaps unsurprising that we don’t see much in the way of woodworking here at Hackaday; after all, this is a plastics and metal community if there ever was one. But that doesn’t mean you’ll never come across a situation where a dead tree needs to be cut or shaped to your will, so we appreciate [Eric Strebel] demonstrating some tips and best practices for working with this exceptionally versatile building material.

The first video assumes you’re a lumber neophyte, and goes over topics such as the different species of wood you’re likely to find at the hobby shop, proper sanding technique, and the differences between cutting with and against the grain. Some of the different cutting tools you can use are also covered, ranging from the humble hobby knife to the band saw. As always, [Eric] sprinkles the video with tips and tricks gained from his considerable professional experience, such as using some glue and a bit of sawdust to fill in any gaps left behind by an uneven joint.

In the second video, things start getting more advanced. [Eric] demonstrates how you can create custom laminates, and how wood can be permanently bent into arbitrary shapes with sufficient steam and clamping pressure. By combining these new techniques with the basic concepts covered in the first video, surprisingly complex shapes can be formed with minimal effort.

[Eric] previously put together a similar series of videos on working with acrylic, a material that’s arguably far more familiar to the Hackaday readership. But whatever material you use, the takeaway message from this series is clear: get the right tools, learn the techniques, and professional results are well within your reach.

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One Wood Ring To Rule Them All

August 31, 2021 by Danie Conradie 3 Comments

[Olivier Gomis] did not have access to the fires of Mount Doom to forge a large replica of the One Ring, so he had to settle for patience, maple, and a wood lathe. It does have the added convenience of not needing to fire to expose its true nature, just angry pixies from a wall socket.

[Olivier] made the ring in separate inner and outer sections from 72 blocks of maple. The blocks were glued together in 12-sided rings, and stacked in layers to achieve the desired width. The surfaces were cut smooth and thinned out on a wood lathe, and an internal channel was created for LED strips. The Black Speech was cut through the walls of both the inner and outer surfaces using a manual router. Using the ring itself as a former, he made a wooden base for the router to allow it to slide across the surface without wobbling.

The inside wall was cut into sections and glued into a recess in the external portion. The inscriptions were covered with a maple veneer, which still allows it to be visible when the internal LEDs are switched on. The wiring runs from the base of the stand through an S-shaped stem that was made from layers of veneer clamped in a former. A total of 53 hours of painstaking effort went into this work of art, but the end product would make any hardcore Lord of the Rings fan envious.

For more LOTR-themed hacks, check out the secret door to the Mines of Moria secret door, and a sword that glow blue in the presence of unsecured WiFi.

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Wooden Keyboard With Scrabble Tiles Goes The Extra Mile

August 3, 2021 by Kristina Panos 18 Comments

[Steve M. Potter] loves and respects a good, solid keyboard as much as we do and wanted to build an heirloom-level battleship to grace their home office. Well, you couldn’t ask for a better donor keeb. [Steve] used a Unicomp, the modern Model M. The cases on them are nowhere near as nice as a real model M, but hey, where else are you going to find a keyboard with new buckling spring switches? You’re not. (If anyone has a line on new buckling spring switches by themselves, please let us know.)

Although it has those wonderful buckling spring switches, this body is made of solid cherry. After dialing in the general shape of the case, [Steve] carefully routed out all the key cluster holes using a plunge router. This appears to have been the easy part, because making the keycaps looks terribly tedious.

The alphas a number row are all made from 3/4″ maple dowel rod cut down into cylinder nuggets and topped with Scrabble tiles. The F keys and modifiers are cut out of square poplar rod with bird’s eye maple veneer for a unique look. We particularly like the colored F keys — they look like candy or whisky stones, and just happen to be in resistor color code order. But our favorite part has to be the Caps Lock light. We’ll never understand why in situ lock lights went out of fashion.

Like the look of this keyboard but don’t have this much time to invest? Macropads look good in wood, too.

Guitar With Hot-Swappable Pickups Lights Our Fire

May 11, 2021 by Kristina Panos 17 Comments

There’s a story that goes something like this: Chet Atkins was playing his guitar when someone remarked, ‘that guitar sounds great!’ Mr. Atkins immediately stopped playing and asked, ‘how does it sound now?’ While it’s true that the sound ultimately comes from you and your attention to expression, we feel that different pickups on the same guitar can sound, well, different from each other.

However, this is merely speculation on our part, because changing pickups is pretty serious surgery, and there’s only one company out there making guitars with hot-swappable pickups. Since their low-end model is out of most people’s price range, [Mike Lyons] took one for the team and decided to build a guitar from scratch to test out various pickups of any size, from lipstick to humbucker. [Mike] can swap them out in under a minute, and doesn’t need any tools to do it.

[Mike] modeled the swapping system on that one company’s way of doing things, because why reinvent the wheel? The pickups are inserted through the back and held in place with magnets and a pair of cleverly-designed printed pieces — one to mount the pickup to, and the other inside the pickup cavity.

As far as actually connecting the things up, [Mike] went with a commercially-available quick-connect pickup solution that uses a mini four-conductor audio plug and jack. The body is based on the Telecaster, while the headstock is more Stratocaster — the perfect visual combination, if you ask us.

We are particularly fond of [Mike]’s list of caveats for this project, especially the requirement that it had to be built using only hand tools and a 3D printer. Although a drill press would have been nice to use, [Mike] did a fantastic job on this guitar. Whether you’re into guitars or not, this is a great story of an awesome build.

What, you don’t even have hand tools? You could just print the whole guitar instead.