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August 5, 2009

MAKE workbench project

MAKE Flickr pool member Jeff M built this shop workbench using the instructions from Weekend Projects. In fact, it was our first Weekend Projects podcast (sniff, sniff), from July 7, 2006. Ah, that was a simpler time...

Weekend Projects - Make a Workbench

Workbench

August 4, 2009

DIY electronics iPhone app

Hipster Logic has released an iPhone electronics reference app, called, well... Electrical Ref. From their iTunes description:

Have you ever wondered how many Ohms that resistor your holding is? Maybe wondered what the capacitance is of a ceramic disc capacitor with the code 103? Forgotten how to assemble a 555 timer circuit? Or wondered how to make your Arduino detect an EMF? Then Electrical Ref is the app for you. It features a resistor calculator, capacitor calculator, & circuit diagrams.

The app costs a buck.

Electrical Ref

Unfortunately-named yet awesome retro tool

I love old-style manually-operated tools. They frequently feature in my survivalist fantasies: the zombies come, the power grid collapses, and I'm the only one left who can still build killdozers because all my tools are manually-operated. Then one day Alyson Hannigan runs screaming into my compound, in terrible distress and in dire need of my assistance. It kinda goes downhill from there.

Anyway, this manually-operated drill is designed so that the operator can apply the weight of his or her body to the drilling action by leaning against the rearward brace. It is, most regrettably, called a "breast drill," a name that obviously dates to ye gay days of old. They are still being manufactured, and are available through our pals at Garrett-Wade.

August 3, 2009

Caliper pen

Das original! It's the German-made Messograf caliper pen from Cleo Skribent. Built into the retractable ballpoint pen is a 4″ Vernier caliper that measures in increments of both 0.1mm and 1/16″. The pen also functions as a metric screw thread scale and a tire tread depth scale. Garrett-Wade carries them.

Always Have Calipers On Hand

Don't forget your soldering challenge!

It's Lucas again, our poster child for the MAKEcation Family Soldering Challenge. Here he is (note: safety glasses this time!) working on his second soldering project, a Drawdio. Lucas (and family) get a free Maker's Notebook because they posted pics of their MAKEcation to the MAKE Flickr pool. The next four people who post their pics will also get a free notebook.

And don't forget, we're giving away a $100 gift certificate to the Maker Shed for our favorite family soldering photos/videos and five Best of MAKE or Best of Instructables books. Adafruit industries has also generously given us some of their awesome soldering merit badges to give out to winners. But you've gotta upload your pics!

More:

August 2, 2009

Tips on "unpresenting"

I spotted these sketchbook notes by Austin Kleon on Flickr, of a presentation that Heather Gold gave for VizThinkU. I wasn't at the talk, but it's amazing to me how much of the gist of it these two pages seem to convey.

Heather Gold on unpresenting for VizthinkU

July 31, 2009

Diamond-blade dicing saw from hard drive

Over at the mightyOhm, Jeff Keyzer has a guest blogger, his friend Tony. Tony's first project posted is (part 1) of this awesome diamond-bladed precision chop saw he built with parts from hard drives. The motor, pivot bearing, and motor driver are all from old drives. The blade is a surplus wafer-dicing blade, 300µm thick!

Tony's Diamond Chop Saw (Part 1)

Mint-tin key carrier

When I first saw this, I didn't think it seemed like such a bright idea -- maybe because of how it apparently beats the crap out of the tin and because this guy carries a lot of keys. I only carry three and a flat LED keyfob flashlight. And I always carry a tiny-tin Altoids box with my meds in it. I'm always looking to consolidate the contents of what I carry -- cut down on that chipmunk-cheeks pocket bulge -- so maybe I'll experiment.

Keychain box

July 30, 2009

Akro-Mils storage cases

One of my upcoming Toolbox columns is going to cover shop storage tech. So I was happy to see this positive review of Akro-Mils storage cases in today's Cool Tools:

Working in industrial design, I constantly acquire small sets of parts to use for multiple clients and projects. I've tried using a variety of translucent plastic boxes to contain and organize these parts, but they've been flawed in a number of ways: the parts are difficult to pick out with your fingers; the small pieces migrate from compartment to compartment; and finally, the latches break.

I think Akro-Mils has solved all of these problems with their cases. The latches span the entire front side of the organizer, work well, and don't seem to break. The bottom of each compartment is curved on at least two sides to allow picking up those 0-80 screws, and the top has ridges that surround each divider to make it much less likely for the parts to jump out of their compartments. The two Akro-Mils organizers I have been using are the small (05-705) and the large (05-905). There's a medium available, too. I think I paid $4 and $7, respectively, which is about the same price as products with none of these features or durability. -- Arthur Carr

Akro-Mils

July 28, 2009

Hack Junk's Seattle Power Tool Race entry

Dave and Dave from Hack Junk decided, sort of at the last minute, to enter the recent Seattle Power Tool Race and Derby. The video documents their build and their two race attempts.

Hack Junk

July 27, 2009

Steampunk multitool?

Here's an interesting take on the multitool, it's called a Harp Tool ($40), because it resembles something of a harp when it's closed. Tools include slotted- and Phillips-head screwdrivers, punch/awl, saw, corkscrew, file and small/large-head hammer (which doubles as a bottle opener). Stored in a leather carrying case.

byrd 8Tool Harp [Thanks, Daniel Carnes!]

How-To: Pointer weight for SMD soldering

Gerrit points out this simple yet quite helpful tool he made for keeping squirrelly surface mount parts in place for soldering -

This simple tool will change your life. I was lucky to learn how to solder surface mount from a master. He had crafted a tool very similar to this for himself and used it daily. The design is simple, a weighted pin is attached to a piece of round stock and this holds the part down on the board. Using this tool I soldered an entire surface mount board with no errors on my first try.

Very cool - perhaps teaching your family to solder surface mount parts is the logical next step? ;) Head over to Gerrit's blog for the basic instructions.

How-To: Make your own stick solder dispenser

In response to my Your soldering tips post, "Gizmo" at CircuitGizmos Labs sent this little write-up on creating your own solder dispensing tube using the little tube containers found at hobby and craft stores. - Gareth

It is very easy to make a small solder dispenser. This is nice way to keep solder in your toolbox or pocket without it becoming tangled, crushed, or unruly. The solder coil is protected in the transparent container, the end of the solder feeds out of the top of the tube for use.

The little container I use was purchased at a hobby store. You might also look in the bead supply department of craft stores. The Sharpie is the right diameter to use as a form for wrapping the solder. A pencil will also work, but produce a smaller coil. A larger coil holds the most solder and prevents "bunching up" as the solder is dispensed. My big roll of solder is perched on a CD holder spindle that's weighted on the bottom.

A small hole is drilled in the container's cap. An 1/8 inch hole works well.

Slip the end of the solder into the cap of the Sharpie to hold it in place. The solder runs from the Sharpie's lid down the length of the marker.

Wrap the solder back over itself, coiling the solder toward the cap of the Sharpie. When finished, clip the solder close to the body of the marker. Remove the marker lid and free the coil of solder.

Insert the end of the solder that was held by the Sharpie lid through the drilled hole in the container. Assemble the dispenser by sliding the coil into the clear body tube.

The plastic containers come several to a pack. This allows you to make several and scatter them wherever you might need solder, or dedicate one to lead-free solder. One improvement might be to glue a magnet to the bottom of the tube - the magnet, stuck to an appropriately heavy object, would help hold the solder dispenser in place as you use it.

July 24, 2009

Let the MAKEcation solder-fest BEGIN!

Well, we've completed our first week of our MAKEcation programming, "Teach Your Family to Solder." We hope we've inspired you to take up the firesticks, grab some noxious metal on a spool, and start dripping beads of molten alloy all over sensitive electronic components. Good, clean fun for the whole family!

Win awesome booty!
If you and family members DO decide to learn soldering, document it. Take photos and/or video and send us the links. Load them onto the MAKE Flickr pool and tag them with "MAKEcation." At the end of August, the Maker Media staff and soldering Camp Counselor Dave will be choosing the most interesting, entertaining, creative entries. Our favorite will get a $100 Gift Certificate to the Maker Shed! Five other entries will get a choice of a copy of The Best of MAKE or The Best of Instructables. We'll also be giving away some Maker's Notebooks too. So gather the family 'round and get crackin'

Don't forget:
You can send any questions, comments, suggestions, and links to your MAKEcation media to Camp Counselor Dave at campcounselor@makezine.com.

And: We have a specially priced "Teach Your Family to Solder" bundle in the Maker Shed, with three easy-to-build beginner kits in it, a copy of MAKE, Volume 01 (with soldering tutorial), and a Maker's Notebook). A significant deal at only $36.

Here's a wrap-up of the week's soldering-related content:

Let's take a Summer MAKEcation!

MAKEcation: "Teach Your Family to Solder" week

Super learn-to-solder roundup

Camp counselor Dave's soldering tips

YOUR soldering tips

Lucas learns to solder

A brief history of my soldering experiences

Toolbox: Soldering essentials, part 1

Toolbox, Soldering tools, part 2

YOUR solder tips!

We thought it'd be fun to poll Make: Online readers to collect some of YOUR top soldering tips. Please share your pearls of wisdom in the comments for those who may be new to the alchemical art of turning lead into electronics.

Here's one tip that's a perfect example of a "why didn't I think of that?," something really simple that can prove amazingly useful. We've posted it before, but it bears repeating. It was first posted in my Toolbox: Jigs, clamps, and helping hands">clamps and jigs Toolbox column:

Here's a soldering trick that was a revelation to me the first time I saw it. It's not really a jig, more like using the material, in this case, solder as itself a jig/helper. Dave Burton, of Dorkbot DC took this picture for us and writes: "A fellow DC Dork asked for a visual aid after I was unable to describe this soldering technique via email. Basically, you coil up a piece of solder and let it serve as a jig for you, but since I've already proven my inability to describe it verbally, here's my attempt at modeling it. This is a piece of Radio Shack perfboard, with my butane soldering iron, and a diode sticking out of the perfboard in the back. Note the technique of coiling the solder on the table and reaching one end upward. I can't remember who taught me this technique (neither could my fellow dorks), but it has saved more soldering hours than every other jig, clamp, and hack that I've got.

More:
Camp counselor Dave's soldering tips

Workbench NES system

I don't know how much work Miltron is going to get done in his shop, now that he's built and installed this nifty little game system on his bench. It's built using a NoaC (NES on a Chip) and a cannibalized PSOne LCD screen. Yet another use for The Maker's Notebook -- as a game controller wrist-rest.

DIY Workbench playable NES [Sent by Hector of Make:en Español. Thanks, Hector!]

A brief history of my soldering experiences

My first soldering iron was the kind that our camp counselor, Dave Hrynkiw, recommends we never use. You know the kind, it comes in a $10 kit and barely works. The reality is, a lot of people find one on these irons in the bottom of their toolbox and start their soldering careers with it. Big mistake.

I ended up with a few burnt boards, traces that lifted, and an overall sour taste for soldering. It's a shame that I was so frustrated, because soldering really isn't difficult. You just need the proper tools.

Fast forward about a year later. I picked up a nice mid-priced Weller iron. Unfortunately I can't remember the model, but it had selectable heat and it worked great. I remember ordering a MiniPOV kit from ladyada. I was able to solder it together fairly easily. In fact, I was successful in making lots of kits, even a couple of CNC controller boards, which I still use today. Now that I look back on it, it wasn't my improved technique so much as having a decent iron.

About a year ago, I was hanging out at adafruit in NYC and asked Limor about her soldering iron recommendations. Her immediate answer was "Buy a Metcal." I searched eBay and found a used one for about $120. It came with two tips and a nice heavy stand. I turned it on, and in about five seconds it was up to full heat. I pulled out some scrap parts and did a little test-soldering. Limor was right, this iron was amazing!

The pen has a really nice feel, it's lightweight, and the handle never seems to get hot. The solder melted perfectly, and everything went together so easily. I've been happily soldering with it ever since.

Keep in mind, I'm not suggesting everyone go out and drop $120 on a soldering iron, it just isn't necessary. However, do take Dave's advice and don't bother with a super-cheap one. Spend $25 and save yourself a lot of misery.

What kind of soldering iron do you use? Let us know in the comments, it will serve as a useful resource for everyone. Thanks!

July 22, 2009

Toolbox: Soldering tools, part 2

In the twice-monthly Make: Online Toolbox, we focus mainly on tools that fly under the radar of more conventional tool coverage: in-depth tool-making projects, strange or specialty tools unique to a trade or craft that can be useful elsewhere, tools and techniques you may not know about, but once you do, and incorporate them into your workflow, you'll wonder how you ever lived without them. And, in the spirit of the times, we pay close attention to tools that you can get on the cheap, make yourself, or refurbish.

This week, as part of "Teach Your Family to Solder Week," we're looking at what you need to get started in soldering. In Part 1 of this Toolbox, we looked at essential tools. In this installment, we'll look at some of the support tools that can make soldering more enjoyable, go faster, be less fumey, etc.

We've written about the "Dry Solder Tip Cleaners" (aka "Cleaning Genie") a number of times. They're sold under different names, but it's basically a little container of metal shavings that you clean the solder tip in (instead of the damp sponge found on most spring-type soldering stands). Elliot Williams of HacDC writes: "Tip cleaner/tinner is good for rejuvenating oxidized tips, but cleaning your tips with one of these metal sponge thingies makes it almost unnecessary in the first place. Rant #25692: Water rusts/oxidizes metal. Oxidized metal doesn't transfer heat well. Why the hell would you ever want to touch your soldering iron tip to a sponge with cold water in it?"

You can easily make your own such cleaner by getting a copper scrubby pad at the grocery store and stuffing it into a small container.

A solder dispenser is not really an essential tool, but can come in very handy, especially if you're doing a lot of near-production-line soldering. Scott Austin, of Dorkbot DC and Dorkbot Baltimore, says: "A larger project of mine (over 60 dip sockets in each of two projects) required lot of soldering. I bought a solder dispenser and borrowed a friend's soldering station. I was able to solder the sockets (700-800 soldering joints) very quickly with this set-up."

While we talked about solder suckers and solder braid in the last Toolbox, there's also the desoldering bulb (which works similarly to the sucker). Scott Austin says: "A desoldering bulb works pretty well. But you do have to work quickly: heating the joint with the iron and then positioning and using the bulb before the solder cools. If you find yourself desoldering a lot, I really like the combination desoldering iron/bulb tool. They're not that expensive and you don't have be doing the dangerous juggling between soldering iron and solder sucker."

Read full story

Camp counselor Dave's soldering tips

We asked our MAKEcation Camp Counselor, Dave Hrynkiw, to share with us some of the common mistakes he sees newbies making when learning to solder. He shares some of his thoughts below.

Dave is the geek behind the woman (hey Cheryl!) who runs the Solarbotics and HVW Technologies. He's our virtual Camp Counselor during "Teach Your Family to Solder" week. If you have any questions for Dave related to soldering, send email to campcounselor@makezine.com.

Using Too Little Heat: This is an issue when you're using those wimpy 10- or 15-watt pencil-type soldering irons. They're usually purchased as part of a set which includes some murky solder, a useless soldering-iron "stand," and a "what is this thing for?" mini-wrench, used for replacing the tip (trust me, the iron ain't worth that effort). The idea behind soldering is to heat the item, and then melt the solder to the item. In most electronics situations, that item will likely be a wire, or an electronic component. When you have an iron that generates wimpy amounts of heat, trying to heat up the item will take longer than it should, which will usually lead to damaged components from excessive heating, or a messy solder job (because the builder got impatient and melted the solder to the tip and tried to "paint" the molten solder to the joint). Either situation is bad. Save those wimpy irons for burning your name into a piece of wood, or roasting marshmallows from the inside-out (but don't eat them! - bet that iron isn't lead-free/RoHS compliant).

Using Too Much Heat: We often see kits come in for repair that have been scorched like they've been soldered with a butane torch! Sometimes they have! Or with one of those huge pistol-grip soldering guns designed for soldering 12-gauge car trailer connections in mid-winter Alaska. A printed circuit board's copper traces are barely more than glued onto the phenolic or fiberglass substrate we call a PCB. Too much heat kills this adhesive layer, making traces and pads lift from the board like a bad sunburn two days after that bender on the beach (sorry for that imagery, but it's pretty accurate). Go easy with the firestick, chief. The boards and components are made to withstand a certain amount of heat in the soldering process, not the heat of a solar flare.

Painting: This is the most common newbie mistake. As mentioned under "Too Little Heat," soldering is the process of heating the items you want to solder together, and melting the solder to those items, using the heat in the items (as transfered by your iron). It's the reverse of painting. The (wrong) painting method is melting solder onto your iron, then trying to smear it onto the item you're soldering. What you end up with is a solder job that will most likely flake right off. You want to paint? Try the Bob Ross-style class at the local community college (Jeez, I miss that guy -- and his tremendous hair). Think of the soldering iron as a gravity gun for solder. Stick the iron where you want the solder to go, and when you apply it, the solder will naturally flow towards the heat. You can't convince solder to go where there's no heat. It's kinda like a retired Canadian that way.

Appriopriate Tools, Equipment, and Supplies: I bet you think I'm going to suggest getting the best soldering iron you can afford, right? Nope. A decent low-cost iron is fine. If you stick with electronics long enough to thoroughly wear out a medium-quality 20-to-30 watt pencil-type soldering iron, then go ahead and buy something fancier. Spend about $25 on a iron (not a kit!) and you'll be all set.

Solder comes in many types and flavors, the most common being "Lead-free" and "Lead/Tin." Given a choice, I'll take leaded any day. There's a reason all military-grade electronics are still done with lead-based solder. It's just better. It melts at lower temperatures, flows better, and ends up looking shiny when applied properly. The other stuff looks like crud, even when it's done correctly, which is especially troublesome for beginners looking for proof of a healthy join. Yes, there are lead-based dangers, but use some common sense, good ventilation, and don't eat while you're working (solder/fingers, fingers/sandwich, sandwich/brain, brain/dumb), and wash your hands well with soap when you're done.

Secondary to the leaded/non-lead solder issue, there's the decision of "no-clean" vs. "rosin" flux. OK, there are more types, but those are the main types. Flux is a chemical paste that's usually in the core of the solder you use. When you melt it, the flux cleans the surfaces and "lubricates" the soldering, making the metals bind correctly. If you have a choice, get a "no-clean" flux, as the other types will make your solder joints look like burned sugar.

In short, get a $25, 20-to-30 watt pencil-type soldering iron, a $12 1-lb. roll of no-clean lead/tin solder (that's lots - share with family and friends), don't floss with the solder, and don't paint it onto your projects.

Bonus Tip: Get a container of Multicore "Tip Cleaner." Best $3 you'll spend on a soldering accessory. It will triple the life of your solder tips, and make almost any gungy tip look clean and shiny again. Just don't breath the fumes when you push a hot dirty tip into this pumice-like substance.

More:
Toolbox: Soldering Essentials, Part 1
Toolbox: Soldering station tools and hacks

July 21, 2009

Solarbotics' soldering summary

[Click on image to enlarge]

Dave Hrynkiw, who runs Solarbotics and HVW Technologies, is our virtual Camp Counselor for "Teach Your Family to Solder" week. One of the things I love about Solarbotics' kits is that they always have excellent, and funny, documentation. Each of these instruction booklets includes the brief soldering tutorial posted above. Really, that's all the basics you need to know. We'll have more detailed tutorials, tips, videos, etc, throughout the week, but armed only with this "quick reference card" and the basic tools, as outlined in my Toolbox column, you'd have what you need to solder successfully. If you're going to be teaching people how to solder, print out the above and have it on-hand for your students.

If you have any questions for him related to soldering, send email to campcounselor@makezine.com.

More:
Toolbox: Soldering essentials, Part 1
MAKEcation: "Teach Your Family to Solder" week
Let's take a Summer MAKEcation!

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