StructuredChaos

Well, the time came that I needed to redo the foam on the Surfjet.  The board weighed in (with 1/2 gallon fuel) at 183 pounds.  This is about 45 pounds more than it was supposed to.  I tried to extract the water from the foam using a vacuum pump but this was a futile attempt and I should have saved the money I spent on fittings etc.

Cutting the board open isn’t that hard…used the circular saw set to 3/8″ as suggested to avoid cutting into the hydraulic throttle tubing.  This would have worked had the tubing been in the right place…as it was there was no way to avoid it and I ended up cutting through my brand new hose assembly…..ouch.

The pictures shown are my current progress.  The ordering of the pictures is off for some reason. I have to redo the fire extinguisher housing, it was rotted out.  The original was a cardboard tube they fiberglassed over.  I opted to try some 4″ sewer tubing, making a mounting flange out of some stiff foam board.  The same foam board will be used for the end cap as well.  As long as I can get the angle right it should work out.  The foam, when replaced, should hold it firmly in place.
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When I cut the top of the board off it delaminated.  There is a layer of corrugated cardboard in the middle.  I used the fiberglass epoxy, mixed with some Cab-o-sil, to glue it back together.   It took 8oz of epoxy for the whole piece but seems pretty sturdy.  Hopefully I didn’t change the contour too much…I guess I will find out later!

Nearly 6 months have passed and what did I accomplish on my previous list?  Not a whole lot!  I did get the wall of storage up in the office…freeing up room and organizing things a bit.  As expected the office is now a different mess….I have more things than we have wall space.

Destination Imagination has been crazy this year, as usual.  Caden’s team made it to State and then to Globals.  They are in the final stages of finishing their changes for Globals…just in time as they have 2 weeks to get there.  Destination Imagination takes over everything.
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All other projects are still on hold.  The trailer needs to be done, I will have 3 weeks to finish that before the Rally.  I also need to replace the seals in the General Lee motor and rebuild the starters.  That will be my goal for the 3 weeks after DI is done I guess.

Ok, so having (undiagnosed) ADD is a struggle in many cases but it also has it’s upsides.  I get to take on a LOT of projects that really sound fun.  Here is a list of as many unfinished projects as I can think of:

• Raspberry Pi - Tiny computer that I bought, haven’t even looked at what to do with it.  One idea is a mini jukebox (with audio out to tie into a full sound system) with a tiny screen.
• Mini CNC - Yep, this is still not completed.  I need to replace the beds with better surfaces…Acylic is what is called for and may be what I use.  The worst problem is the Z axis has a lot of deflection.  I did use it just last night and it almost works….redesign of Z axis needed.
• MAME machine - This project is still in the works…some progress made on deciding on the design and some on the hardware and software sides.  I need to purchase the materials to just start building!
• Wetbike Trailer - I converted a boat trailer for Wetbike and Seadoo use.  It desperately needs to be stiffened as it uses 3″ channel and has a lot of flex (too much weight I am sure).  I had to extend it 3″ and move the axle…thank goodness for neighbors with welders!  This has to be done before next spring/summer for sure.
• Wetbike Motor - I have a wetbike motor that needs new lower seals (water gets in when it just sits) and 1 motor that needs rebuild (taken apart on my workbench for a long time now)
• Wetbike Starters - I need to rebuild 3 Wetbike starters.  I have the parts, just need to do them!  I need to get a press for this I think (finding a place to put it will be hard
• Book Cases/wall - We want to build a full wall of bookcases/shelves for the office so we can organize it.  We don’t use it as an office but it has a lot of computer parts and other stuff that could use organization and would also help Megan organize her craft/sewing stuff.
• Floors - We need to redo at least the linoleum portions of our floors.  We would like to do wood laminate (found one we like) but we haven’t decided yet about tile or laminate in the kitchen…water getting under is a concern and pulling the floor up to fix it would be a pain!
• Bathroom - Our bathroom needs tiles floors, the shower redone and the tub side redone.  Would be great to do new counters and change the cabinet (at least color) as well.
• Mini3 amps - I built 2 headphone amps 3 years ago and they need a part replaced.  The new parts have been ordered (twice now)…just have to take the time to solder them.  They are surface mount which will be tough as other components will be in the way!
• Wireless Throttle Control - I purchased the XBEE parts to do a wireless throttle using RC servos.  I ended up not needing them but I would still like to see if I could design something around it…might be useful as some point!
• Edge Lit Signs - I have an idea for some Edge Lit LED signs I want to build.  I really need my CNC working for this (and accurately as well).  I also need to source some cheap Acrylic to practice/play/build with.  I also want to try a Chess Board (I have chess pieces I ordered to make boards for many years ago).

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So that is about as many as I can think of off the top of my head…I know there are more, just have to remember them (or come up with them)

Again I realize I am the only one reading this, right now at least, but I must apologize for my extended absence.  As usual I got sidetracked to other projects.  I won’t promise there will be more updates but we can always hope…

As a quick update…Hottub is in and good…took days not hours to setup.  Caden’s Destination Imagination team went to Global Finals in 2011 and then again in 2012 when Megan and I coached them.  We are coaching them again this year along with a team for Sarah.  Good luck to them!
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There are some big projects coming up…Arcade machine(s) are hopefully on the short list.

Caden has been participating on a “Destination Imagination” team with 5 other kids.  The basis of DI is that the kids do the work, and the parents act strictly as “coaches”.  The kids are to use discovery methods to find the best way to solve problems.  It has been interesting watching how they come to their conclusions, how they address issues, and how incredibly hard it is not to interject the coaches ideas into the kids.

While I have enjoyed this project, I am looking forward to it finishing this weekend.  As we are now in the final days, it has gotten VERY busy…which makes all other efforts hard to find time for.  My Hot Tub is waiting to be wired, but I still need to get my gravel, which means I need to borrow my neighbors truck.  Of course the best times to do this are taken up by DI at this point.

I estimate I am 4 hours from having the Hot Tub ready to fill.  It shouldn’t take more than 2 hours to move the gravel in and level it, another hour to get the Hot Tub in place (this needs some help/thought as it weighs a lot), and an hour to run the electrical…maybe more on that part as crawling through the attic is sure to be loads of fun!
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Once I get the Hot Tub in place, I still need to replace the 2 missing jets, and then start filling it.  Nothing can happen to test the functionality until it is full, nor can I learn how to use the hardware and the controller.  Lots of guessing and trial/error in my future.  I should be able to run the electrical while the Hot Tub is filling, so hopefully I won’t be waiting around for that.

I should post pictures of the project…maybe next time.

Hot Tub party at my house!!!!

Yes, I am aware that I am talking to myself as I haven’t given this link to anyone, but I can still be excited.  Megan agreed to let me buy and install a hot tub.  I have struggled with an aching back for years and years (I would say decades but I don’t want to remind myself that I am getting old).

I was browsing Craigs List, and I found a very nice tub for only $400.  The owner had originally been asking $700, but will soon be moving into an apartment and won’t be able to take it with him.  The tub was located in Plano…about 20 miles away.  I went and looked at it, and it was nice.  It would need rewired as the control panel was damaged in the last move.  It was also missing some jet internals, but those are replaceable.  Unfortunately, it didn’t have a cover.

I planned to pick it up the next day, if I could get a trailer.  I had a line on one, but it wasn’t available.  I didn’t feel my watercraft trailers would be up to the task, given the 8′ dimensions and the weight and distance and all.  I instead made a arrangements for the following weekend.
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That same evening, as I was perusing CraigsList, I saw a listing from someone also in Little Elm….giving one away!  I emailed the lister, and gave my name, email and phone number.  I was called back, and went to check it out.  It was only a 7′ tub, but it was fully working, had nicer controls, and only needed 2 jets replaced.  As it turned out, it was only 1/2 mile away, so I converted a trailer to handle it, and picked it up on Monday the 14th, with the help of some friends and neighbors.  Hot Tubs are HEAVY!

I had to build a place to put the tub, and also purchase the wiring I would need.  I was able to buy the sub-panel from the previous owner, so I only needed 75′ of wiring and a 50 amp 240V breaker.  I opted to build an 8×8 box of 2×6′s, fill it with gravel, with cemented supports in the middle to stop the weight of the tub from spreading it out.  My brother Nathan was in town for the day, so he helped me dig some holes and pour cement…much appreciated!

At this point I am waiting for my wire to arrive, and the chance to go to the gravel yard to buy a ton (literally) of gravel.  I doubt I will get the chance any evening to do any work, but maybe Saturday I will get some time!

I would guess I have done my part to pave the “path to hell”…what with all my good intentions regarding my garage/DIY projects.  I hit a bit of a wall with the Mini-Mill, the Z axis needs re-engineered as it has a lot of movement when the Y axis moves.  Given this distraction, and the arrival of the parts to build the 3W LED headlight…I started on that project.

My neighbor has a shark fishing hobby.  When possible he spends a weekend at the gulf.  Much of the fishing is done in the dark, which is not a nice time to be low on light…especially when you are waist deep in the water.  We had discussed multiple options, and I recalled some LED DIY headlights I had seen.  I ordered the various bits to make 2 copies.

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Powering the lights is the real struggle…balancing between portable and long life.  I opted for the initial build to use an 18V NiMH drill battery…$10 from Harbor Freight and $5 for a charger.  This was by far the cheapest option, and is still very portable….just somewhat heavy.  Christian took the prototype to a fishing get-together…I am looking forward to the feedback he obtained.  I don’t have a lot of desire to built them to sell, but I agreed to do a few for him and his friends that would want them.  There is still some tweaking needed on the headlight straps etc….more to come (with pictures too!)

Limits. Limits are good, especially when it comes to machines that can cause damage to themselves or other materials they work on! So far with the mini-mill (I really need a name for it), all the table movement limits have been software defined. The table knows it can’t move more than 10” on the X axis, 4” on the Y axis, and 5” on the Z axis. This works fine unless one of the motors locks up and the software thinks it moves but it doesn’t…throwing off the counting. Besides causing problems with the current milling that is happening, it opens the potential for the machine to run past the limit on a movement.

The documentation for the controller and the Mach3 software talk about using limit switches, but the design I adapted from didn’t have any in place, and I hadn’t considered them until it became obvious that I needed some…the machine jumped time and then ran the table into one of the motors. No damage was caused, but it did motivate me to install some limit switches.

Home Switch for Z Axis

Home Switch for Y Axis

Luckily I had a bunch of switches from my unfinished Arcade project. The little switches that go on the buttons can be used in either a N.C. (Normally Closed) or N.O. (Normally Open) configuration. The Controller software is designed for N.C. switches…meaning the switch allows continuity unless the button is pressed. All the switches are linked in series, so if one switch is press, the whole circuit is broken. I installed one switch for the “home” as well as the “max” limit on the X and Y axis, and one switch for “home” on the Z axis. I didn’t use a “max” limit on Z as it would be dependant on the cutting tool length.
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Two considerations had to be made. I didn’t want a lot of wires strung around to get caught on things, and I sort of wanted the switches to be hidden. I managed this by installing the X axis switches under the table that moves, with a stop installed on the rail at each end of the run. The Y axis switches are visible, but close to other wiring and hardware so they won’t get caught on anything and stressed…used very small wires as that is all that is required. I scavenged some ribbon cable I purchased from AllElectronics for this, and used the .187 female spade terminals I also bought for the Arcade project. It sure helps having the right stuff on hand!

Hiding under the table....the X Axis switches

X Axis Limit Stop

Once I configured the switches in MACH3, the mini-mill was now able to “home” itself. It does this by moving one axis at a time to the “home”…it knows when it breaks the circuit that the axis being moved is responsible, and then it backs off and proceeds with the next axis. This has the effect of re-centering the machine each time, which is helpful as previously I had been doing it by eye.

I made a temporary fix to the X axis…it limits my movement much more than I want, so I will be redoing it in the very near future.  I started tinkering with Gcode, and manually entering it.  I had to wrap my head around the idea that Z go negative to cut into the part I am engraving (with the way I have it set currently).  I have never used the engraving bits I had, so I didn’t know how deep they could cut etc.

First I tried some foam, just so I didn’t much a bit…good thing to because I thought I was defining in 1/1000 of an inch, instead of inches…that could have been bad.  Once I got everything figured out, I was able to produce my first (not round) circles.  I need to stiffen up the motor supports and the dial in the backlash.

First four circles I cut

The GCode for this was fairly simple.  I did it one line at a time, next I will try writing it in a text editor first so I don’t have to keep typing stuff in.  The code went something like this:

G1 Z-.05     –This sets the router bit .05 inches below the surface

G17 G3 I.4   — This specificies an arc (circle) that is .4 inches radius, and is to the left of the router, on the centerline

J.4   —The G17 (circle) and G3 (CW rotation) from above are held as variables, so this simply cuts the same sized circle above the router bit (top circle in the picture).
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I-.4  –This cuts the right circle

J-.4  This cuts the bottom circle

G1 Z.5  This raises the router .5 inches above the work surface.  I had to redeclare the G1 linear movement to override the G17 circular movement.

Yep, pretty boring, but that was worth 1 hour of my evening!

Here is a shot of the whole mill:

I made this!