Posts will appear intermittently over the next week or two.
I’m still spending an inordinate amount of time studying the back of my eyelids while horizontally polarized in the lift chair. I can highly recommend not doing whatever it is that triggers a pinched lumbar nerve, but as nearly as I can tell, the proximate cause (shredding leaves) isn’t anything close to whatever the root cause might be.
It does provide plenty of time to conjure solid models from the vasty digital deep:
The wheelchair brake lever seems to have been designed by somebody who never actually had to shove it very often:
After powering my Sony HDR-AS30V helmet camera for nearly all of this year’s riding, the Batmax NP-BX1 lithium batteries still have roughly 90% of their original capacity:
Those are hot off the Official Batmax charger, which appears identical to other randomly named chargers available on Amazon.
They’re holding up much better after a riding season than the DOT-01 batteries I used two years ago:
Empirically, they power the camera for about 75 minutes, barely enough for our typical rides. I should top off the battery sitting in the camera unused for a few days, although that hasn’t happened yet.
Of course, the Batmax NP-BX1 batteries I might order early next year for the new riding season have little relation to the ones you see here.
That’s the 5 mm punch, where being (at least) half a millimeter off-center matters more than it would in the 32 mm punch.
Unscrewing the painfully awkward screw in the side releases the pilot:
The debris on the back end of the pilot is a harbinger of things to come:
Looks like whoever was on spring-cutting duty nicked the next coil with the cutoff wheel. I have no idea where the steel curl came from, as it arrived loose inside the spring.
Although it doesn’t appear here, I replaced that huge screw with a nice stainless steel grub screw that doesn’t stick out at all.
Chucking the pilot in the lathe suggested it was horribly out of true, but cleaning the burrs off the outside diameter and chamfering the edges with a file improved it mightily. Filing doesn’t remove much material, so apparently the pilot is supposed to have half a millimeter of free play in the handle:
That’s looking down at the handle, without a punch screwed onto the threads surrounding the pilot.
Wrapping a rectangle of 2 mil brass shimstock into a cylinder around the pilot removed the slop:
But chucking the handle in the lathe showed the pilot was still grossly off-center, so I set it up for boring:
The entry of the hole was comfortingly on-axis, but the far end was way off-center. I would expect it to be drilled on a lathe and, with a hole that size, it ought to go right down the middle. I’ve drilled a few drunken holes, though.
Truing the hole enlarged it enough to require a 0.5 mm shimstock wrap, but the pilot is now pretty much dead on:
Those are 5, 6, 8, and 10 mm punches whacked into a plywood scrap; looks well under a quarter millimeter to me and plenty good enough for what I need.
Adding a bit of trim to the bottom of the LED spider makes it look better and helps keep the strut wires in place:
It’s obviously impossible to build like that, so it’s split across the middle of the strut:
Glue it together with black adhesive and a couple of clamps:
The aluminum fixtures (jigs?) are epoxied around snippets of strut wire aligning the spider parts:
Those grossly oversized holes came pre-drilled in an otherwise suitable aluminum rod from the Little Tray o’ Cutoffs. I faced off the ends, chopped the rod in two, recessed the new ends, and declared victory. Might need better ones at some point, but they’ll do for now.
Having helped grossly over-fund the Atreus Kickstarter earlier this year, a small box arrived pretty much on-time:
I did get the blank keycap set, but have yet to screw up sufficient courage to install them. The caps sit atop the stock Kailh (pronounced, I think, kale) BOX Brown soft tactile switches; they’re clicky, yet not offensively loud.
Removing a dozen screws lets you take it apart, revealing all the electronics on the underside of the PCB:
The central section holds most of the active ingredients: