Archive for the ‘Mechanical’ Category

Earbud-Wrap Business Card

Sunday, May 15th, 2011

I made one last (for now) modification to my Credit Card Earbud Holder. The wrap now ends with an over-pass that really locks everything in place. As before, it’s insanely easy to remove the wrap.

Bundle slides right off
<2 Second Removal

The other thing I realized is that, if laser cut from thin plastic, this would make a really neat business card. I don’t really feel like paying for a laser-cut version at the moment, so I just printed out a shipping label to illustrate. If you DO feel like laser cutting this bad boy, I’ve uploaded the plans to Thingiverse. (The plans will also help you if you just want to make one out of an old card)

UPDATE: I got some of these laser cut. They look amazing.

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My Take on the Credit Card Earbud Holder

Thursday, May 12th, 2011

Yesterday on Lifehacker they posted a forehead-smack idea. Take a credit card, cut it up a bit. You’re left with a free, light, earbud holder. I’ve got a bunch of old cards lying around, so I made one.

Bud Holder - Theirs

I Didn’t like it. My design grievances:

  • You wrap in the short direction, which means more wrapping to get the job done
  • Having the earbuds stored on either side means you need to put in each bud individually
  • It takes just as long to unwrap as it does to wrap

It needed some work to compete with my current method. The beauty of using cards is that they’re easy to work with and plentiful (in my house at least.) It only took about an hour (7-10 iterations) to settle on a winner. Meet my new earbud holder:

Bud Holder - Mine
Bud Holder - Mine

  • The earbud slots are wide and next to eachother, so you can get the buds in quickly with one motion
  • You wrap the long way, so you’re done in half the time
  • The way the plug is clipped ensures that the wrap stays put, but…
  • Because the wrap isn’t in channels, it slides right off once the plug is detached. WAY faster.

UPDATE: I went through a few more iterations and came up with an improved design.

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Google is Keeping the Offset Header

Wednesday, May 11th, 2011

I have a one-track mind whenever I see a new Arduino variant. My eyes drift to one spot to see if the offset is still there. Naturally I did the same thing when I saw that Google is releasing its own Arduino-type thing

Lo and behold, there’s the telltale gap. I’ll need to look at any schematics they wind up open-sourcing, but I’m fairly certain: Sparkfun will be selling these for a while longer.

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DIY Safety Razor Handle

Saturday, March 6th, 2010

DIY Safety Razor

It’s terrifying.  I’m still in shock that it actually works, but it totally does. One dollar of materials and two or three hours of work, and I now have a safety razor of my very own.

Why? Why would you do something like this?

Basically, I’m cheap and I like making things for myself. I’d been toying with the idea off-and-on since reading a Lifehacker post on safety razors. It all came together for me this past week.


dimension extraction

I was looking at an image from an old razor patent when inspiration struck. Based on the known razor width and some trigonometry, I was able to determine that the two main radii were 0.53″ and 0.66″. It turns out that these are almost identical to 3/4″ and 1″ sch40 pvc, which is available everywhere.



Sorry. No mid-build pictures on this project. I never thought it would work. This was supposed to be a study of sorts, just seeing how things might work in further iterations. Instead it worked, and I’m stuck trying to give the gist of it…

  1. Cut a piece of 3/4″ pvc slightly bigger than the desired top piece.
  2. Wrap sandpaper around some 1″ pvc and sand down the botton edge of the 3/4″.
  3. Cut a section of 1″ pvc for the bottom piece.
  4. Make holes in the top and bottom pieces.
  5. Run a bead of jbweld down the center of the top piece.  as it hardens shape it into a ridge.
  6. After the jb hardens, sand such that it just fits the blade’s slot.
  7. Remove material from the bottom piece to make room for the jb ridge.
  8. In theory, you’re done!  In reality there’s some fine-tuning to do.  It took me about an hour of trial-and-error sanding until I was happy with the final shape of the top piece.

I’m going to shave with this for awhile, and when I make the next one I’ll try to be more diligent about documentation.

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REALLY deconstructing a Doodle Pro

Wednesday, November 25th, 2009

I didn’t really “deconstruct” the doodle pro in the last post. I split the housing apart with a screwdriver, and I didn’t even show pictures! What a gyp. For those of you that are interested in a little more, here you go:

Doodle Pro - Layers Separated

I pulled apart the drawing panel. It looks like it’s made up of two sheets of plastic. One is embossed with a honeycomb, and the other is then fused over-top. I really had to yank to get these apart, so I’m guessing they used some heat to melt them together.

Inside there’s metal shavings and a PUTRID smelling liquid. You know how cherry, watermelon, orange, etc flavors don’t taste like the real thing? Imagine if the same people were asked to make something that smells like feet. That’s the best analogy I can think of: synthetic feet smell.

Oh man, if you could…

Now the million dollar question… could someone DIY one of these? Maybe using a clear plastic mesh and two thin sheets of the same plastic? I think the hardest part would be dealing with the liquid. It needs to be viscous enough to hold the shavings in place, it needs to be opaque, and the plastic layers need to be fused closed with the liquid in place.

If you could make one in the 3′ x 4′ range, the payoff would be huge. Even if you don’t do what I’m thinking with it, it would still make a kick-ass whiteboard replacement.

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Deconstructing a Doodle Pro (a.k.a Magna Doodle)

Wednesday, November 18th, 2009

I’ve been really intrigued by various Etch-A-Sketch automation projects out there (here’s a few.) I’m excited by the prospect of a large, diy, low energy display. I’d love to use one to make a web-synced wall calendar. I can see two major hurdles in the The Etch-A-Sketch route though: You can’t lift the pen, and you need to shake it (or redistribute the powder somehow,) to erase the drawing.

Doodle Pro

I went around and around in my head, trying to figure out how to overcome these issues, when my girlfriend says, “Why not use a Magna Doodle?” Why not indeed! The erasing process is just a swipe of a magnet, and there’s no aluminum dust to contend with. Much easier. (I should mention here that while I have always known this toy as “Magna Doodle,” that’s a discontinued name. Fisher Price bought it and renamed it “Doodle Pro.”)

There’s a wrinkle though. Unlike the Etch-A-Sketch, the Doodle Pro needs the pen to be on the viewer’s side of the screen. That would probably be ok, but ideally I’d like all the display hardware to be hidden from view. What to do, what to to?

Doodle Pro Test - FrontDoodle Pro Test - Back

Well, I got some cheap Doodle Pros today, and upon taking one apart, it looks like that may not be an issue. It turns out that when you draw something on one side, you get a decent negative on the other! So I’m going to try, at least at first, to create a display with the pen hidden from view. The user will see a black (gray, I guess) background with white lines. The lines are a little fatter than I’d like, but there may be some improvements that can be made to the pen that will fix that.

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Saturday, October 10th, 2009

chugging along

Constant Air + Constant Heat = Constant Smoke. Who knew?

Constant Air

pre-patch JBpost-patch

Holes. There were tons of holes. To have complete control over the air I had to patch them all. Most of them were fairly easy. A little JBWeld and aluminum foil and I had rigid, (fairly) high temp patches. All the seams got a bead of JB for good measure as well.

repositioned ramp

The biggest hole of all was at the front, where the toaster door used to be. The box was essentially open. What I did there was rotate the entire box 90 degrees, making that opening the top. The ramp needed to be repositioned, but that wasn’t too hard. Now the gaping hole was on the exit side of the chamber, where leaks aren’t as important.

The cover for this hole was also upgraded. Where before it was covered using a big piece of foil, I finally used something better: a nice metal sheet with a 3″ outlet pipe.

Constant Heat

thermistorThermistor Location

In the previous attempt I had scrapped the stock themostat and switched to SSR control of the heating elements. I set it to a fixed value, walked away, and the whole thing promptly caught on fire.

This time around, I added a thermistor to the mix. It’s amazing what a little feedback can do. As far the control algorithm, I didn’t bother using the PID library (*gasp*.) For a process this simple all it took was a back-of-the-envelope P-only controller. It held the temperature and SSR output constant, and more importantly, things didn’t catch fire.


As before, I used a blow-drier fan for vibration. This time, however, it was mounted on the OUTSIDE of the box. It vibrated well -10 seconds every 15 minutes- for the duration of the test. It also didn’t melt into a pile of goo, which was a definite plus.


this is why we're here

I’m ecstatic.   All my success criteria have been met! The Smoke was consistent, and by restricting the air inlet I was able to adjust smoke density.

I put in a pound of wood (3 large chunks), and this thing ran for 5 hours straight before the smoke started to die down. There’s room for 3-4 Times as much wood in there, so an 8-16 hour run time is attainable.

Next Steps

As far as proving out the concept, I’m pretty much done. All that’s left for this phase of the project is to smoke some meat.

Beyond that I’d like to improve the design from a DIY standpoint; making it as easy to copy as possible.

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DIY BBQ Smoke Generator – 2nd and 3rd Attempts

Friday, September 25th, 2009

I’ve had a few more gos at making smoke and, well, there’s still work to be done.

2nd Attempt

not bad for 3 bucks

There were two main issues with the first attempt. The smoke was intermittent, and I needed to manually shake the ramp. In the second attempt I tried to take care of both problems with one stroke.  I mounted a fan to the underside of the ramp. This would induce air circulation, and the spinning would vibrate the ramp. I settled on the fan out of a a hair-drier. The idea was appealing for several reasons:

  • An old hair drier is $3 at the thrift store.
  • A hair drier uses 120V AC.  I wouldn’t need a separate source to power it
  • It’s a fan.

Fan mounted to ramp

So I got the fan out and mounted it to the ramp.  It turns out that this idea wasn’t all that good.

  1. Mounting the fan in the middle of the ramp like that did little to improve circulation.
  2. The fan didn’t vibrate all that much
  3. It turns out the motor was actually DC.  They use the heater coil as a resistor to get the voltage they need, then rectify it with a diode.  It’s a brilliant, low cost solution for them.  It was a pain in the butt for me.
  4. The fan was LOUD.  You know, like a hair drier.

So other than learning how a hair drier is wiried, attempt 2 was pretty much a bust. I got the same smoke performance from a louder unit that needed a 12V power supply.

3rd Attempt

The fan didn’t really do much in the second attempt. It didn’t vibrate, and didn’t improve airflow. In the 3rd attempt I tried to fix both problems.

To increase the fan’s vibration, I decided to give it a little off-center weight. Inserting a screw into one of the blades shifted the center of gravity, and made it vibrate like a champ.  This didn’t do anything to help the noise / circulation issues though.  I try to be nice to my neighbors whenever I can, and 4-5 hours of vibrating hair drier noise just isn’t nice.

So I shifted gears. Instead of a constantly vibrating fan with on-off heat, I decided on an intermittent vibrating fan with more consistent heat. Since the initial smoke issues were caused by the On-Off heat control, maybe a more constant heat would lead to constant airflow / smoke. The Fan was relegated to vibration duty, turning on periodically to help the wood settle.


I built an arduino sheild (yes I used an offset header) to:

  • Send a 25% output to an SSR controlling the heaters. 
  • Vibrate the fan for 5sec every 10 min (more than enough to help the wood settle)

Great plan right?  I got everything set up, saw the smoke start, and walked away for 30 min.  Anyone know what happened next?  Anyone?  Yes.  You in the back.  The heaters added more and more heat to the chamber?  More than the air could remove,  even though the airflow was increasing with temperature?  You’re right!  I had suspected that this might happen, just not so quickly. 

…I came back to a fire.  It was contained within the box, and the box was alone on an a stone patio.  There wasn’t any danger, but the fan was cooked.  damn. Here’s some carnage photos where you can see the vibration screw:



So What Now?

I was hoping to be able to macgyver my way through this thing using aluminum foil and tape.  I’m going to have to up my game a bit.  In future attempts I’m going to start from overkill and work my way down, rather than the bottom up method I’ve been using.   So that means:

  • Really sealing the chamber.
  • Using an external fan
  • Using dampers to control airflow in and out.
  • Mounting the vibration mechanism OUTSIDE the fire box so it doesn’t get smoke/fire damage
  • More precise temperature control.  That’s right.  PID control.  I said overkill.  I meant it.

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DIY Barbecure Smoke Generator – First Attempt

Thursday, September 10th, 2009


Some serious progress has been made. We have smoke! It’s nowhere near done, but the results are encouraging. Here’s what’s been done since the last post.

Toaster Tear-down


The toaster I used cost me $10 at the thrift store. The first order of business was to take everything apart. 20 minutes with a screwdriver and some wire cutters, and I was left with the components I needed:

Stripped down

  • A heat-resistant box
  • 2 heating elements
  • A thermostat
  • An extra piece of sheet metal for the ramp (formerly the toaster’s outer shell)


All that stuff is in every toaster, and it’s all I really needed. This was a high-end model apparently, so there was a bunch of extra electronic components in there too. Lots of goodies for future projects. I won’t bother listing them all, but take a look at this picture. Not a bad haul for $10!

Heating Element Relocation

Relocated Heaters

With everything apart, I could start construction. Per the design, the heating elements were relocated to the bottom corner of the chamber. I needed new holes, and as you can see from the picture, I did a terrible job. I should’ve used a sheet-metal drill. Instead I used tin-snips. Oh well. The holes are in the right place, and the heating elements fit.

Ramp Construction

Fabbed RampRamp Inserted

The sheet metal that used to form the oven’s outer shell was cut and bent to form the wood-feed ramp. The inner walls of the box are contoured, so it took several tries to get something that fit nicely.

Thermostat Relocation

Relocated Thermostat

The last thing to do was move the thermostat. Since all the heat was going to be localized in a new place, I figured the thermostat should be nearer to it. I made a new hole in the center of the back, and mounted it there.

Time to Test!


Other than worrying about electrocution and burns, the testing phase was pretty straight forward:

  • I put 3 pieces of apple wood on the ramp so they were touching the heater.
  • Most of the holes in the hot boxwere then sealed with aluminum foil. I left holes for air intake and exhaust.
  • After plugging it in, it took maybe 10 minutes to find the right thermostat setting. I slowly upped the temperature until there was a constant flow of smoke.
  • Beyond that it was just sitting around and basking in the smokey aroma.



Of course there’s lots of work still to be done, but I’m really happy with this first attempt.

The Positive:

  • Those 3 pieces of applewood gave me 5 hours of smoke. I only had to intervene twice; shaking the box a little to get the wood to the heaters. Other than that it was continuous, automatic smoke!

Room for improvement:

  • The smoke density wasn’t constant at all.  When the heaters were on there was a lot more smoke formation (Heat + increased convective airflow.) When they we off the smoke tapered off.
  • Needing to manually shake the ramp violates one of the main design criteria I’m shooting for. This thing should “operate unattended.”
  • Currently the thermostat is out in the open, making it susceptible to ambient temperature changes.
  • It’s a little dangerous.  There’s exposed 120VAC all over the place.

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DIY Barbecue Smoke Generator – Project Kickoff

Tuesday, September 8th, 2009

Smoke Gen

Unlike most of the projects I’ve done in the past, this one is going to be a multi-poster. There’s just too many ins, too many outs. What’s the project? Turn a toaster oven into a high-quality barbecue smoke generator. Aaaaaand go!

First of All, Why Bother?

I’ll concede there’s a certain Zen-like satisfaction that comes from using only fire.  Constantly tending and tweaking,  making sure everything’s right.  I’ve done that, and with some success.  what I want now though, is consistency.  I want to start the process knowing there aren’t going to be any headaches.  I want automation.  It’s a travesty I know, but I’ve come to terms with that.

Design Criteria

Here’s what I’m going for. If I can get the smoker generator to do the following, I’ll consider the project a complete success. It should:

  • Operate Unattended for 8-16 hours.
  • Generate consistent smoke.
  • Allow for adjustable smoke density
  • Accept standard wood.  (No custom bricks, no sawdust, etc…)

Easy right?

The Plan

Smoke Gen Principle

The design I’m going to try is pretty similar to what you’d see in a commercial smoker. The wood is on a ramp that leads to a heating element. A restricted amount of air is allowed to flow past the wood. Because there’s incomplete combustion, lots of smoke is generated. As wood is consumed, ash falls away and new wood takes its place. Gravity may be all I need for that to occur, but I’m guessing I’ll need to vibrate the ramp.

Stay Tuned…

It’ll be interesting to see how it goes. Subsequent posts will detail the construction process, as well as testing and any re-design. If it all fails in a huge ball of fire? Well that will be covered as well.

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