Category: Machine Shop

Mechanical widgetry

PolyDryer Humidity: November

The measurements:

	2025-11-04	2025-11-11				2025-11-19
Filament	%RH	%RH	Weight – g	Wt gain – g	Gain %	%RH
PETG White	39	39	27.4	2.4	9.6%	23
PETG Black	25	26	26.7	1.7	6.8%	14
PETG Orange	30	23	26.5	1.5	6.0%	23
PETG Blue	18	23	27.0	2.0	8.0%	10
PETG-CF Blue	25	25	26.5	1.5	6.0%	18
PETG-CF Black	22	22	26.3	1.3	5.2%	14
PETG-CF Gray	28	28	26.5	1.5	6.0%	18
Empty → PETG Clear	31	n/a	26.8	1.8	7.2%	18
TPU – Clear	28	29	26.3	1.3	5.2%	14
W empty → TPU – K	23	27	26.8	1.8	7.2%	18

All the boxes now have filament spools and 50 g of silica gel divided equally between the humidity meter and the tray in the bottom of the box:

Polydryer Box desiccant tray - installed — Polydryer Box desiccant tray – installed

The PETG White in the first row is the new spool loaded last month. I think the 39 %RH indicates the spools do not necessarily arrive bone-dry in their vacuum-sealed bags with a tiny desiccant packet.

Conversely, both the PETG Clear and TPU K filaments are new spools that seem reasonably dry out of their bags.

The auto-rewind spindle in the PETG Orange filament hasn’t been working quite right, so I opened the box a few times. It now has a new PETG-CF spindle.

2025-11-20

Bird Feeder Tray Mount

The mixed flock attending the bird feeder in the back yard scatters enough seeds to attract the deer, so I added a tray underneath to catch the overspray:

Well, two trays, because it took a couple of iterations to make the solid model match reality:

Bird Feeder Tray Mount - show layout — Bird Feeder Tray Mount – show layout

The n-1 iteration was Close Enough™ and two trays are obviously better than one.

The “trays” are stray lids from the six gallon buckets we use for many purposes, including root-cellaring the vegetable garden harvest. The lid’s solid model was straightforward:

Bird Feeder Tray Mount - lid model — Bird Feeder Tray Mount – lid model

Removing the lid from a solid block produces the most complex part of the mount:

Bird Feeder Tray Mount - mount layout — Bird Feeder Tray Mount – mount layout

An aluminum plate on the outside (the gray slab in the overall view above) distributes the strain from the two M6 screws across the block.

A smaller block on the inside of the lid has a pair of square nuts:

Bird Feeder Tray Mount - segment layout — Bird Feeder Tray Mount – segment layout

All three parts build from their flattest side:

Bird Feeder Tray Mount - build layout — Bird Feeder Tray Mount – build layout

The downward facing clamp arch in the main block didn’t need support, but the square nut sockets in the segment definitely came out better with little support blocks inside; PrusaSlicer does a good job with most support structures.

The n-1 iteration used M6 rivnuts that were slightly too long after making the lid model match reality, so I switched to square nuts. The OpenSCAD code calculates the segment block length to match the actual screws, but 75 mm M6 screws and square nuts are barely long enough.

I clamped the outer block to the lid as a drill guide for the first hole, then pinned the block with a screw to ensure it didn’t slip while drilling the second hole:

Bird Feeder Tray Mount - drilling setup — Bird Feeder Tray Mount – drilling setup

Those were freehanded in the drill press at low speed with serious concentration; some things you just gotta do that way.

The mixed flock overwhelmingly approves the trays, to the extent a dozen birds clamor to use them: definitely a crowd-pleaser!

I’m certain you can buy pole-mounted trays, but what’s the fun in that?

The OpenSCAD source code as a GitHub Gist:

	// Bird feeder tray mount
	// Ed Nisley – KE4ZNU
	// 2025-11-06

	include <BOSL2/std.scad>

	Layout = "Show"; // [Build,Show,Lid,Mount,Segment,Nut]

	/* [Hidden] */

	ID = 0;
	OD = 1;
	LENGTH = 2;

	HoleWindage = [0.2,0.2,0.2];
	Protrusion = 0.1;

	NumRibs = 12; // stiffening ribs
	NumSides = 8*NumRibs;

	$fn=NumSides;

	Gap = 5.0;

	WallThick = 9.0; // robust walls
	Kerf = 1.0; // clamp cut
	TapeThick = 0.5; // wrap around pole

	LidOD = 12; // main diameter in inches

	PoleOD = 1*INCH;

	PlateThick = 2.0; // backing plate for clamp

	Screw = [6.0,12.0,6.0]; // thread OD, washerOD, head
	ScrewLength = 75.0;

	ScrewOC = 60.0; // chosen to clear stiffening ribs in lid

	LidLayers = [ // bottom to top, ID = 0 means solid disk, LENGTH = exterior measurement
	[0,(LidOD-2(3/8))INCH,Protrusion], // 0 – below zero to prevent Z fighting
	[0,(LidOD-2(3/8))INCH,(3/8)*INCH], // 1 – base inside bucket
	[0,(LidOD+2(1/8))INCH,(1/8)*INCH], // 2 – flange
	[(LidOD-2(1/2))INCH,LidODINCH,(7/8)INCH], // 3 – sealing ring
	];

	LidOAH = LidLayers[1][LENGTH] + LidLayers[2][LENGTH] + LidLayers[3][LENGTH];
	LidTopDepth = (3/4)*INCH; // from highest part of interior

	MountBlockWidth = ScrewOC + 2*WallThick;

	BaseSagitta = LidLayers[1][OD]/2 – sqrt((LidLayers[1][OD]/2)^2 – (MountBlockWidth^2)/4);
	echo(BaseSagitta=BaseSagitta);

	PoleOffset = BaseSagitta + ((LidLayers[2][OD] – LidLayers[1][OD])/2) + WallThick + PoleOD/2;

	MountBlock = [PoleOffset + PoleOD/2 + WallThick – PlateThick,MountBlockWidth,LidOAH];
	echo(MountBlock=MountBlock);

	SegBlockOffset = ScrewLength – MountBlock.x – PlateThick; // assumes recessed
	SegmentBlock = [2*SegBlockOffset,MountBlock.y,LidTopDepth];

	Rib = [2*6.0,5.0,LidTopDepth]; // lid stiffening ribs
	RibAlign = 0 * 180/NumRibs; // position ribs wrt mount

	EdgeRadius = 3.0;

	//—–
	// Rivnut
	// The model collects all the magic numbers right here

	/*
	RivnutOAL = 15.0;

	module Rivnut() {

	union() {
	cyl(1.6,d=13.0,circum=true,anchor=BOTTOM);
	cyl(RivnutOAL,d=9.0,circum=true,anchor=BOTTOM);
	}

	}

	*/

	//—–
	// Square nut
	// The model collects all the magic numbers right here

	NutOAL = 5.0;

	module SquareNut() {

	cuboid([10.0,10.0,5.0],anchor=BOTTOM);

	}
	//—–
	// Bucket lid
	// Centered at XY=0, Z=0 at top of exterior flange

	module BucketLid(Interior=true,Expand=false) {

	render()
	union() {
	down(LidLayers[2][LENGTH])
	cyl(LidLayers[1][LENGTH],d=LidLayers[1][OD],anchor=TOP);
	cyl(LidLayers[2][LENGTH],d=LidLayers[2][OD],anchor=TOP);
	if (Interior) {
	if (false)
	down(Expand ? Protrusion : 0)
	tube(LidLayers[3][LENGTH] + (Expand ? 2*Protrusion : 0),
	id=LidLayers[3][ID],od=(Expand ? 2 : 1)*LidLayers[3][OD],anchor=BOTTOM);
	else
	difference() {
	cyl(LidLayers[3][LENGTH] + (Expand ? 2*Protrusion : 0),
	d=(Expand ? 2 : 1)*LidLayers[3][OD],anchor=BOTTOM);
	up(LidLayers[3][LENGTH] – LidTopDepth)
	cyl(LidTopDepth + (Expand ? 2*Protrusion : 0),
	d=LidLayers[3][ID],anchor=BOTTOM);
	}
	up(LidLayers[3][LENGTH] – LidTopDepth)
	for (i=[0:(NumRibs – 1)])
	zrot(i*360/NumRibs + RibAlign)
	right(LidLayers[3][ID]/2)
	cuboid(Rib,anchor=BOTTOM,rounding=1,edges="Z");
	}
	else
	down(Expand ? Protrusion : 0)
	cyl(LidLayers[3][LENGTH] + (Expand ? 2*Protrusion : 0),
	d=(Expand ? 2 : 1)*LidLayers[3][OD],anchor=BOTTOM);
	}
	}

	// Mount clamp

	module Mount() {
	render()
	difference() {
	cuboid(MountBlock,anchor=BOTTOM+LEFT,rounding=EdgeRadius,edges="X");
	left(LidLayers[1][OD]/2 – BaseSagitta)
	up(LidLayers[1][LENGTH] + LidLayers[2][LENGTH])
	BucketLid(Interior=false);
	right(PoleOffset) {
	cyl(3MountBlock.z,d=(PoleOD + HoleWindage.x + 2TapeThick),circum=true,anchor=CENTER);
	cuboid([Kerf,2MountBlock.y,3MountBlock.z]);
	}
	if (false)
	right(MountBlock.x – PlateThick)
	cuboid(3*[PlateThick,MountBlock.y,MountBlock.z],anchor=LEFT);
	up(LidOAH – LidLayers[3][LENGTH]/2)
	for (j=[-1,1])
	fwd(j*ScrewOC/2) {
	cyl(ScrewLength,d=Screw[ID] + HoleWindage.x,circum=true,orient=RIGHT,anchor=BOTTOM,$fn=6,spin=180/6);
	if (false)
	right(MountBlock.x + Protrusion)
	cyl(Screw[LENGTH] + Protrusion,d=Screw[OD] + HoleWindage.x,circum=true,
	orient=LEFT,anchor=BOTTOM,$fn=12,spin=180/12);
	}
	}
	}

	// Nut block segment inside lid

	module NutSegment() {

	render()
	difference() {
	cuboid(SegmentBlock,anchor=BOTTOM,rounding=EdgeRadius,edges="X");
	down(LidLayers[3][LENGTH] – LidTopDepth)
	left(LidLayers[1][OD]/2 – BaseSagitta)
	BucketLid(Interior=true,Expand=true);
	up(LidTopDepth – LidLayers[3][LENGTH]/2)
	for (j=[-1,1])
	fwd(j*ScrewOC/2) {
	left(SegmentBlock.x/2)
	cyl(ScrewLength,d=Screw[ID],circum=true,anchor=BOTTOM,$fn=6,spin=180/6,orient=RIGHT);
	left(SegmentBlock.x/2)
	yrot(90)
	SquareNut();
	}
	}

	}

	//—–
	// Build things

	if (Layout == "Lid")
	BucketLid();

	if (Layout == "Mount")
	Mount();

	if (Layout == "Segment")
	NutSegment();

	if (Layout == "Nut")
	Rivnut();

	if (Layout == "Show") {
	down(LidLayers[1][LENGTH] + LidLayers[2][LENGTH]) {
	Mount();
	color("Orange",0.5)
	up(LidOAH – LidLayers[3][LENGTH]/2)
	right(MountBlock.x + PlateThick)
	for (j=[-1,1])
	fwd(j*ScrewOC/2)
	cyl(ScrewLength,d=Screw[ID],circum=true,orient=LEFT,anchor=BOTTOM);
	}
	up(LidLayers[3][LENGTH] – LidTopDepth)
	NutSegment();

	color("Gray",0.4)
	right(PoleOffset)
	cylinder(3*MountBlock.z,d=(PoleOD),anchor=CENTER);
	color("Gray",0.4)
	left(LidLayers[1][OD]/2 – BaseSagitta)
	BucketLid();
	color("White",0.7)
	down(LidLayers[1][LENGTH] + LidLayers[2][LENGTH])
	right(MountBlock.x + 2*PlateThick)
	difference() {
	cuboid([PlateThick,MountBlock.y,MountBlock.z],anchor=BOTTOM+LEFT,rounding=EdgeRadius,edges="X");
	up(LidOAH – LidLayers[3][LENGTH]/2)
	for (j=[-1,1])
	fwd(j*ScrewOC/2)
	cyl(ScrewLength,d=Screw[ID],circum=true,orient=RIGHT,anchor=CENTER);
	}
	}

	if (Layout == "Build") {
	render()
	union() {
	difference() {
	left(MountBlock.z + Gap/2)
	up(PoleOffset – Kerf/2)
	yrot(90)
	Mount();
	cuboid([3MountBlock.z,2MountBlock.y,3*MountBlock.x],anchor=TOP);
	}
	render()
	right(Gap/2)
	intersection() {
	up(MountBlock.x)
	yrot(90)
	Mount();
	up(MountBlock.x – PoleOffset)
	right(MountBlock.z/2)
	cuboid([2MountBlock.z,2MountBlock.y,MountBlock.x],anchor=TOP);
	}
	right(2*MountBlock.z – BaseSagitta)
	up(SegmentBlock.x/2)
	yrot(-90)
	NutSegment();
	}
	}

view raw Bird Feeder Tray Mount.scad hosted with ❤ by GitHub

2025-11-19

AC Power / Energy Meter

A surprisingly competent AC power-line voltage / current / energy / power meter fits neatly into a mud ring atop a 4×4 inch square electrical box:

AC Power Meter – assembled

The inside view shows the wiring, such as it is:

AC Power Meter – interior

The square black block is the split-core current transformer around the hot line wire, which sticks up just enough in any orientation to require an extension ring, thus a second trip to the Big Box store.

The mud ring has two tabs with threaded screw holes for the device (switch / GFCI / whatever): grab those with a Vise-Grip, flex until they break off, then file down the stub.

Generous globs of hot-melt glue secure the meter in the mud ring. I added a strip of duct tape under the connections in the hope it might avert disaster should either of the AC wires come loose, but my real hope is in the safety ground to the metal box.

The line cord comes from the Box o’ IEC cords, minus its IEC connector, plus the bright yellow USA-ian connector.

Yes, the three metal box pieces and the Leviton connector cost far more than the meter.

Not to code, but good enough for my purposes.

2025-11-18
PolyDryer Box Desiccant Tray

Having used desiccant in tea bags inside the PolyDryer boxes with some success, I wanted to see what happens with more exposed surface area:

Polydryer Box desiccant tray – installed

The tray (jawbreaker boxes.py URL) is 2 mm chipboard with a quartet of additional notches fitting the protrusions in the bottom of the Polydryer box:

Polydryer Box desiccant tray – assembly

Although you’ll find plenty of printed trays, many with ingenious perforated lids, this was quick & easy:

Polydryer Box desiccant tray – cutting

They’re painfully prone to dumping their contents, despite the dividers which are intended to dissuade the beads from taking collective action and surging over the slightly higher outer walls. Fortunately, the dump occurs inside a sealed box and is entirely survivable.

Distributing 25 g of silica gel neatly fills the sections:

Polydryer Box desiccant tray – top view

Now it’s just a matter of time …

2025-11-17
Dryer Vent Filter Snout: TPU Warp

Making the clothes dryer vent filter snout from TPU did not work nearly as well as I expected:

Clothes Dryer Vent Filter Snout – TPU warp

I think that’s the result of applying heat to a slightly compressed rear wall made of bendy plastic.

Making it from much stiffer white PETG required moving the front mounting tabs to the middle to allow enough bendiness to snap them into the vent:

Clothes Dryer Vent Filter Snout – slicer

Although both pieces barely fit on the MK4’s platform, I made the upper ring first to verify the fit:

Clothes Dryer Vent Filter Snout – slicer

If I ever make another, it’ll print as a single top-side-down unit, because the dimensions are now spot on.

From outside, it looks just like the TPU version:

Clothes Dryer Vent Filter Snout – PETG installed

The snood is a cheesecloth tube with shock cord holding it to the snout.

2025-11-14
Humidifier Caster Feet

The ancient and much–repaired Sears humidifier works better in its new location across the living room with its front raised a few millimeters, which may have something to do with its plastic housing supporting a pair of heavy water containers for a few decades.

After fiddling around with shims to find the proper height, these feet descended from the Husky workbench feet:

Humidifier Caster Feet – installed

They’re glued up from 3 mm plywood sitting on a 1 mm layer of cork:

Humidifier Caster Feet – clamping

The humidifier seems much happier with its casters 4 mm above the floor. Seems awfully fussy to me, but there’s no arguing with success.

2025-11-13
Tour Easy: Garage Door Remote Mount

It turns out that keeping the garage door remote clipped to the starboard underseat pack on my Tour Easy attenuated its RF enough that even the directed receiver antenna couldn’t grab enough signal until I rolled onto the end of the driveway.

While contemplating what’s involved in making a 3D model of the remote’s curved backside, I realized the bike already had a perfect spot:

Tour Easy Zzipper Fairing – block mount

A few strips of good outdoor-rated foam tape later:

Tour Easy – garage door opener mount

Believe it or not, the camera is looking through the year-old and unwashed fairing on my bike.

Stipulated: aligning the PCB antenna flat against a small aluminum plate atop a bunch of aluminum bars isn’t perfect. However, enough RF wriggles out to trigger our opener from four houses down the hill, giving it plenty of time to haul the door out of my way.

That was trivial …

2025-11-12