The Smell of Molten Projects in the Morning

Ed Nisley's Blog: Shop notes, electronics, firmware, machinery, 3D printing, laser cuttery, and curiosities. Contents: 100% human thinking, 0% AI slop.

Author: Ed

Respooling Stainless Steel Thread

For various reasons, I needed a smaller quantity of that stainless steel thread / yarn, so I mooched an empty spool from Mary, ran a bolt through it with washers + nut on the far end, chucked the bolt in the lathe, and ran the spindle backwards at the slowest speed:

Stainless steel thread – smaller spool

I started by letting the big spool unroll from the side, but that produced horrible twists in the slack thread. Remembering the lesson from our previous thread spool adventure, I put it on the floor and let the thread pull from the top:

Stainless steel thread – unwinding spool

It still accumulated a huge twist between the two spools, even while guiding it hand-over-hand onto the rotating spool. Either the factory lays the thread on the large spool with a built-in twist or, more likely, a multi-strand steel thread behaves like a spring, no matter what anybody wants, and comes off the spool with a nasty case of inherent vice.

Memo to Self: don’t let stainless steel thread slide through your hands under power, because some of the fuzz visible in the top picture will stay with you.

2016-12-14

Under-cabinet Lamp Brackets

These blocky brackets hold a pair of LED light strips in the recess under our 1955-era kitchen cabinets, to let the light cover the entire counter:

The large holes are for drywall screws into the cabinet, the smaller ones for 2.5 mm SHCS holding the strips to the brackets. I drilled those little holes out and installed 4-40 brass inserts; this being a one-off installation, the source code doesn’t include that change.

There’s not much to see after they’re installed:

Under-cabinet light bracket - center joiner — Under-cabinet light bracket – center joiner

I’d hoped to swap the ends of the strip to power it from the right end, but the guts aren’t symmetric and you can’t just flip it end-for-end:

eShine LED Under-cabinet light - disassembled — eShine LED Under-cabinet light – disassembled

That’s an add-on unit without the IR proximity sensor circuitry and power switch, but with the same overall layout. You take it apart by pressing the obvious latch on one of the endcaps, then gently prying the plastic away from the aluminum extrusion, taking care not to wreck the coaxial socket. Reassemble in reverse order.

The OpenSCAD source code as a GitHub Gist:

	// Mounting brackets for eShine under-counter LED lights
	// Ed Nisley KE4ZNU December 2016

	//- Extrusion parameters must match reality!

	ThreadThick = 0.25;
	ThreadWidth = 0.40;

	HoleWindage = 0.2;

	Protrusion = 0.1; // make holes end cleanly

	inch = 25.4;

	function IntegerMultiple(Size,Unit) = Unit * ceil(Size / Unit);

	//———-
	// Dimensions

	MountHeight = (1 + 3/16) * inch – 5.0; // under-cab space – base thickness

	THREADOD = 0;
	HEADOD = 1;
	LENGTH = 2;

	WoodScrew = [4.0,8.3,41]; // 8×1-5/8 Deck screw
	WoodScrewRecess = 2.0;

	LEDScrew = [2.0,4.5,8.0]; // M2.5×10 SHCS

	LEDScrewOffset = [1.0,8.2,0]; // hole offset from center point
	JoinerLength = 18.1; // joiner between strips

	EndBlock = [11.0,28.5,MountHeight]; // mounting block size for ends

	//———————-
	// Useful routines

	module PolyCyl(Dia,Height,ForceSides=0) { // based on nophead's polyholes
	Sides = (ForceSides != 0) ? ForceSides : (ceil(Dia) + 2);
	FixDia = Dia / cos(180/Sides);
	cylinder(d=(FixDia + HoleWindage),h=Height,$fn=Sides);
	}

	// End mounting block with proper hole offsets

	module EndMount(Side = "L") {

	LSO = [((Side == "L") ? 1 : -1)*LEDScrewOffset[0],LEDScrewOffset[1],LEDScrewOffset[2]];

	difference() {
	union() {
	cube(EndBlock,center=true);
	translate([0,1.5*WoodScrew[1],0])
	cube(EndBlock,center=true);
	}

	translate(LSO + [0,0,-EndBlock[2]])
	rotate(180/4)
	PolyCyl(LEDScrew[THREADOD],2*EndBlock[2],4);

	translate([0,(EndBlock[1] + 1.5*WoodScrew[1])/2,-EndBlock[2]])
	rotate(180/6)
	PolyCyl(WoodScrew[THREADOD],2*EndBlock[2],6);

	translate([0,(EndBlock[1] + 1.5*WoodScrew[1])/2,(EndBlock[2]/2 – WoodScrewRecess)])
	rotate(180/6)
	PolyCyl(WoodScrew[HEADOD],WoodScrewRecess + Protrusion,6);

	translate([((Side == "L") ? 1 : -1)*EndBlock[0]/2,0,0])
	rotate([90,0,((Side == "L") ? 1 : -1)*90])
	translate([0,0,-2*ThreadThick])
	linear_extrude(height=4*ThreadThick,convexity=3)
	text(Side,font=":style=bold",valign="center",halign="center");
	}
	}

	module MidMount() {
	XOffset = (JoinerLength + EndBlock[0])/2;

	union() {
	translate([XOffset,0,0])
	EndMount("L");

	cube([JoinerLength,EndBlock[1],EndBlock[2]] + [2*Protrusion,0,0],center=true);

	translate([-XOffset,0,0])
	EndMount("R");
	}
	}

	//———-
	// Build them

	translate([0,0,EndBlock[2]/2]) {
	translate([-(JoinerLength + 2*EndBlock[0]),0,0])
	EndMount("L");


	MidMount();

	translate([(JoinerLength + 2*EndBlock[0]),0,0])
	EndMount("R");
	}

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Kitchen Light Bracket.scad

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2016-12-13

The Thrilling Adventures of Lovelace and Babbage

We’re reading Sydney Padua’s The Thrilling Adventures of Lovelace and Babbage as our evening story, so I gave a Lightning talk at the MHV LUG meeting last week:

MHVLUG – Lovelace and Babbage – Book Report

Earlier versions of the ~~comics~~ graphic novel are on her blog, including several stories that didn’t make the final book cut.

Highly recommended; if you don’t have wet eyes occasionally, you’re entirely too hard-hearted.

You should read Ada’s Analytical Engine Programming Guide; that’s not her title, but that’s what she wrote. If you’ve ever done any assembly language programming, you’ll feel right at home.

Also, get historical documents, commentary, and Analytical Engine emulators (!) at Fourmilab.

Makes me wish I lived in that Pocket Universe, it does:

econ3_005 – Brunel

That picture is ©www.sydneypadua.com, Creative Commons Attribution-NonCommercial 4.0 International License. There exist T-shirts & mugs.

2016-12-12
Pheasant Sighting

I rolled the bike around the corner of the garage, saw something move, and spotted an exceedingly agitated Ring-necked Pheasant atop the shredded leaf compost:

Pheasant in compost bin

He ran back and forth on the pile inside the cage, apparently having forgotten he had wings, while I fumbled with the camera. Just after I took the picture, he managed a short-field takeoff and flew away through the trees away from me.

A pair of female pheasants then emerged from the forsythia behind the pile at a dead run, made a hard turn to their left, and ran off in the general direction the male had flown. One of the pair seemed smaller and may have been a chick this year, but it’s hard to say.

We haven’t seen any pheasants in the yard before and hope they return …

Taken with the Canon SX-230HS through a layer of deer netting, alas.

2016-12-11
Satco PAR30 LED Floodlight vs. Halogen

I replaced a dead 75 W halogen PAR30 bulb over the kitchen sink with a Satco S9415 LED bulb that was, at the time, advertised as “75 W equivalent”:

Satco S9415 PAR30 LED Bulb – specs

It’s noticeably less bright than the surviving halogen bulb, which is what you’d expect when 950 lm goes head-to-head with 1100+ lm (based on casual searching), but with a similar color temperature and beam pattern, so it’s Good Enough. I should have bought two and converted the halogens into glass sculptures.

The difference between the 22.8 year Life and the 3 Year Warranty always seems amusing. The warranty requires returning the bulb, so that’s about useless …

2016-12-10
Kinesis Freestyle2 Keyboard vs. Linux

My old Microsoft Comfort Curve keyboard having gotten on in years, I picked up a Kinesis Freestyle2 (KB800B for PC) split keyboard:

Kinesis Freestyle2 – desk layout

The little hinged dingus (“Pivot Tether”) between the halves (“Keying Modules”) has two posts that pop into into sockets on the back of the halves and are retained by the two sliding latches. The cord connecting the halves allows 9 inches of separation; I don’t need that much, but more than zero seemed about right.

Kinesis also sells various staggeringly expensive (IMO) doodads that attach to the back of the keyboard to “tent” the middle upward with varying degrees of refinement. None of the doodads offer to raise the back of the keyboard, which I vastly prefer to the current flat or reverse-tilted recommendations.

The keyboard & trackballs rest on a homebrew shelf that slides out from where the desk used to have a center drawer, which puts the keyboard slightly above elbow height (heck, slightly above thigh height), whereupon tilting the keyboard puts the keys exactly where they should be. I bandsawed some wood into vaguely triangular sticks, topped them with foam sheets, and tinkered for best tilt. Works for me, anyhow.

The Compatibility section of the Freestyle2 User Manual describes the “special driverless hot keys”: Most will also work with Linux. Four of them do not work, to the extent that they don’t even send key codes to exv. Some searching suggests this is an intractable problem, for reasons that make no sense to me. Their HID Usage Codes, whatever that might mean:

Kinesis Freestyle2 – inert key codes

That’s only a minor inconvenience; I prefer a physical calculator and don’t spend much of my life listening to anything through the headphones.

For whatever it’s worth, the scroll ring on the most recent warranty replacement Kensington Expert “Mouse” (I think it’s the third) has worked flawlessly for years; they seem to have fixed the sudden death syndrome.

2016-12-09
Sakura Micron Pen Widths

A bag of the Sakura Micron pens I was adapting for the HP 7475A plotter, before the generous donation of New Old Stock plotter pens arrived, come in a variety of useful widths:

Sakura Pens

This relentlessly organized doodle happened while reading some tech docs on the Comfy Couch:

Sakura Pen Width Examples

The first two lines obviously belong in their own group, but, hey, it’s a doodle.

The two Uni-Ball Kuru Toga pencils, in 0.5 and 0.7 mm, have diamond-impregnated lead that’s supposed to be much more break-resistant than usual. I fear that they’ll land point-downward and wreck the rotating sleeve surrounding the lead, so I’ve managed zero drops so far. Even I hesitated at the 0.3 mm version.

They had me at “0.20 mm” …

2016-12-08