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Make A Super Easy 9V Emergency USB Charger

Michael Klements
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Make A Super Easy 9V Emergency USB Charger

This guide shows you how to build a really easy and cheap 9V emergency USB charger. Its perfect to take along on camping trips or leave it in your backpack or your cars glove box. The switch disconnects the battery from the electronics so the battery doesn’t get drained over time and can last for years until you need it in an emergency.

Always check your wiring and the output of the USB socket before connecting your devices to it. Use this guide at your own risk, we take no responsibility for damage caused to your devices due to this circuit or faults with the circuit.

What You Need To Make Your Own 9V Emergency USB Charger

  • 9V Battery – Buy Here
  • 9V Battery Clip On Lead – Buy Here
  • Switch – Buy Here
  • L7805 5V Regulator – Buy Here
  • Thin Heat Shrink Tubing – Buy Here
  • Heat Sink – Optional For Longer Life – Buy Here
  • USB Socket (From Old PC) Or USB Extension Cable – Buy Here
  • 3D Printer & Filament For Housing, Alternately Your Can Use An Altoid Or Similar Tin
  • Optional Mini 5V Solar Panel For Solar Charging – Buy Here

emergency usb charger components required

How To Make Your Own 9V Emergency USB Charger

Assemble The Circuit

The circuit is pretty straight forward and doesn’t require a bread board or component board to mount everything on, you can simply solder the wiring between the components and insulate the ends with a bit of heat shrink tubing or insulation tape.

emergency usb charger circuit diagram

To start, solder the positive wire (red) on the battery lead to one terminal on the switch. Then solder a jumper wire onto the switch which will be used to go to the input pin of the regulator. Remember to slip of piece of heat shrink tubing over each wire before soldering, it can then be slid up over the joint and shrunk with a lighter or solder iron to secure it.

soldering 9V battery clip wire onto switch

switch connections

Now solder the jumper onto the input pin of the regulator, this is usually the left pin when viewed from the front. Solder the negative wire (black) from the battery clip onto the centre pin of the regulator.

solder battery clip to regulator

Next, solder a jumper lead from the output pin (far right pin) of the regulator to the 5V pin on the USB socket or the red wire on the USB cable. Then solder a jumper lead between the centre pin of the regulator and the 0V pin on the USB socket or black wire on the USB cable.

solder USB wires to regulator

If you’re using a USB socket, the pins should be identified on the socket or on the board it is mounted on. You’ll only be using the outer most of the four pins which as the 0V and 5V pins, sometimes identified as GND and Vcc.

If you are using a USB extension cable, cut the socket side off leaving a lead the length you’d like your charger to have. There should be four wires inside, red, white, green and black. The black is the 0V, negative or ground and the red wire is the 5V, positive or Vcc wire, these are the only two wires you need to strip and solder to.

solder regulator output to USB socket

Your circuit is now complete,  double check your connections and your soldering before switching it on.

completed charger circuit

It’s a good idea to check the output on the USB socket before trying to connect a device to it. Use a multimeter and check that the output on the two outer terminals within the socket is reading 5V or reasonably close to 5V |(within 0.2 of a volt).

checking voltage output on USB port

If you are not getting any output, first check the switch, then that the battery is charged and finally check your circuit connections. If you socket is showing a constant and stable 5V then you can try connecting a device and it should start charging.

You may want to add a heat sink onto the regulator if you are going to be using your charger for long periods of time to keep it from overheating, this will dramatically extend its life. Simply place the regulator into the slot on the heat sink and use a rivet or bolt and nut in order to secure it.

adding a heat sink to regulator

Putting The Components Into A Housing

Once you’ve assembled the components, you’ll need to put them into a housing. An old Altoids tin or something similar usually works well otherwise you can 3D print your own using the models below.

super easy 5V emergency usb charger housing

Emergency Charger Housing & End Cap – Download Files

The model allows enough space inside to store the 9V battery with clip as well as the regulator with a small heat sink. There are two holes on the end, one for the USB socket and the second for the switch. The opposite end is open and is closed off with the 3D printed end cap.

housing being 3d printed

Using The 9V Emergency USB Charger

To use your charger, simply plug your device’s USB cable into the socket and turn the switch on.

Super Simple 5V USB Emergency Charger

With the switch off, the battery is disconnected from the circuit and the charger can be stored for a few years (depending on the battery quality) without running flat. It’s therefore perfect to leave in your cars glove box or your backpack for emergencies.

You can replace the battery with a rechargeable 9V battery if you use the charger regularly however after long standing periods the rechargeable battery will run flat.

Emergency USB Charger Improvements

If you’d like to improve on the USB charger and make it slightly more functional, here are a couple of modifications you can make to it.

Enable iPhone Charging

An iPhone won’t charge on this charger with the centre two pins of the USB socket left open circuit. You’ll need to add the following circuit onto the centre pins in order to “fool” the iPhone into thinking that it is connected to a proper charger.

iphone resistor connections

Simply connect the GND to your black 0V wire and the +5V to the output of your regulator.

Smooth Out The Voltage

Add a 100uF capacitor across the input and a 10uF capacitor across the output of the voltage regulator to smooth out any voltage spikes or dips. This makes the chargers output a bit more reliable and protects your connected devices.

Enable Solar Charging

You can easily turn this charger into a solar charger by replacing the 9V battery with a small solar panel such as this one.  Simply solder the positive and negative leads from the panel in place of the battery clip and you’re ready to start solar charging.

You could also try making your own solar panel, its really easy and cheap to build.

Have you built this charger or another USB charger? Let us know in the comments section below. We would love to see your designs and tips.

12 Unusual Projects Using Nails

Michael Klements
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0
12 Unusual Projects Using Nails

Nails have formed part of handymen, tradesmen and DIY fans for thousands of years as hooks, fasteners pegs and hangers but, with a bit of creativity, they can also be used for a number of crafts and projects. Here are 12 of the most interesting projects we have found which use nails in a less traditional way.

Decorative Miniature Knives

Have you even seen miniature knives made from nails? We love this creative project which also teaches you a bit about metal working. The twisted handles look great and the guide, Miniature Knife by pennabilli, covers annealing and forging your own knife.

decorative miniature knives

Nail Puzzle

This classic puzzle has been around for many years. The idea is fairly simple, bend two in such a way that they connect together and come apart in a certain way however the guide, Puzzle, is a bit trickier than it seems.

nail puzzle

Vintage Magnetic Bottle Opener

This is a super easy project and it is certainly one of the more creative. This vintage Magnetic Bottle Opener by mikeasaurus is clean and simple, perfect for a beginner.

Magnetic Bottle Opener (top image) by mikeasaurus

Nail Jewelry

Here are a couple of jewelry items which you can make using nails,  Horse Shoe & Cement Jewelry, author Fikjast Scott.

nail jewelry

Add Decorative Accents

If you’ve got some wooden objects which you’d like to add some accents to, use nails. Check out how AverageJoesJoinery made these great coasters, How to Make Drinks Coasters With Inlay.

add nails as accents

Pin Art Toy

Here’s a guide, Pin Wall by rimamonsta which shows you how  to make your own pin art toy which uses  pins to produce a duplicate 3D shape on the front of the board of whatever is pressed onto the back of the board.

diy pin art toy

Calipers

After you’re done forging knives and some jewelry, you could try making your own tools as well. Here’s a small caliper made by forging and soldering. The guide, Caliper From Wire by Pricklysauce, teaches you techniques which could be used to make all sorts of tools and implements.

nail calipers

Reclaimed Hammer

Speaking of tools, here’s a hammer which is made entirely from old rusty nails. Timsway shows you how to Make a (Working!) Steampunk Hammer.

make a hammer from old nails

If you enjoy reclaimed projects, have a look at these ideas for turning old pallets into useful furniture for your home.

Nail Games

Games involving driving a nail into a block of wood have become a tradition in bars and taverns around the world. Check out How to Play (Stump) by smithallen_studio.

nail games

Trick Box

Similar to the nail games, can you figure out how to open this box? Small nails are an integral part of this Trick Opening Box by author Fathomlis, follow the guide and you’ll also find out how to open it.

trick box

String Art

String art is fairly well known and is also really simple to do. Here are two great examples of string art made with a wooden board, a couple of nails and some string. The techniques used to make a string artwork are pretty simple so its the perfect project for a newbie. Here is a String Art `World Map´ project by He Se.

string art world map

Balancing Nails Puzzle

Here’s another puzzle/game themed project. Can you balance a handful on top of the one in the wooden block? Have a look at this project, Balance 10 on One by somebullcrap, to find out how and make your own coffee table puzzle.

balancing nails puzzle

And that’t it. Now you’ve got a couple of ideas to use nails in extraordinary ways. Have you thought of or seen any other creative uses? Let us know in the comments section below!

How To Give Some Old Chairs A Makeover

Michael Klements
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0
How To Give Some Old Chairs A Makeover

Do you have some old chairs lying around in your attic, garage or basement? Give them a new lease on life with an easy makeover. More often than not, old chairs are made from better quality wood than modern chairs so they’ll serve you better in the long run. Here’s how you can turn your old chairs into modern and usable chairs to fit into your home’s theme.

What You’ll Need To Give Your Chairs A Makeover

  • Old Chairs To Makeover
  • A Rubber Mallet – Buy Here
  • Mouse Type Orbital Sander With 180 Grit Paper – Buy Here
  • Good Quality Wood Glue – Buy Here
  • Clamps or Some Rope – Buy Here
  • Wood Primer – Buy Here
  • Latex Paint – Buy Here
  • Paint Brush & Small Sponge Roller – Buy Here
  • 40mm Foam For Each Seat
  • Fabric To Recover Each Seat
  • Industrial Stapler – Buy Here

How To Give Your Chairs A Makeover

Start off by dismantling the chair, you’ll want to take apart any joints which are loose or broken. Often the old dowel joints in wooden chairs work themselves loose over time and result in a wobbly or “loose” chair.

start by dismantling the chair

Use a rubber mallet to work the pieces loose, protect the wood with some newspaper or an old towel to prevent the mallet from damaging the wood.

If you’re not good at remembering which piece fits where then number each joint’s pieces with the same number as you take them apart, this way you’ll know exactly which pieces go where. You’ll be painting the chair afterwards anyway so the numbering will be hidden.

Now take a mouse sander or rotary tool and clean up any old glue left on the joints, you want there to only be wood left. You can also clean up any scratches, splintered edges and scuffs while you’re busy with the sander.

clean up all joints with the sander

Now glue the chair back together with a good quality cold wood glue. Use a couple of clamps or some rope to clamp/tie pieces together as they dry to get strong joints.

glue the pieces of the chair back together

You can also add in a few pieces in hidden places to brace or support the chair for extra stability and strength.

add in a few pieces for strength

Once the glue has dried you can start with painting. Use a brush and small sponge roller to paint a coat of good quality primer onto the frame. If your chair is in good condition and doesn’t have a dark varnish then a primer may not be necessary.

paint the chair in your colour choice

Follow the coat of primer with a few coats of your coloured latex paint. If you like the look of chalk paint, you could try making your own inexpensive chalk paint?

Finally the seat can be re-covered. If the chair is really old then the chipboard base of the seat may need to be replaced.

Cut a section of 40mm foam to cover the chipboard base. Position the fabric over the base and foam and trim it so that it generously overlaps the edges. Flip the seat over, pull the fabric tight and staple it to the underside of the seat. Pull out any kinks and staple the fabric firmly until you have a neatly covered seat.

the completed chair

Screw the seat back onto the chair and your chair is now complete.

Have you given a chair or other item of furniture a makeover? Let us know in the comments section below, we’d love to see your before and after pictures. If you enjoyed giving your chairs a makeover, perhaps you’d enjoy flipping some other furniture as well?

This post is based on Chair Makeover by donc146 and has been modified and used under the Creative Commons license CC BY NC SA 2.5.

Make Your Own Super Cheap Windowsill Greenhouse

Michael Klements
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0
Make Your Own Super Cheap Windowsill Greenhouse

Greenhouses are a great way to look after plants or germinating seedlings. They help to increase humidity and temperature, shield plants from pests as well as to moderate temperature changes. In this guide, we will show you how to easily create a convenient mini greenhouse that can be placed on a window sill, using only scavenged items that everyone has access to. It has lots of space and height for plants to grow in, and can be customized to accommodate more or different types of plants.

What You’ll Need To Build Your Own Windowsill Greenhouse

  • Wooden Skewers or Kebab Sticks – Buy Here
  • A Clear Plastic Bag or Sheeting – Buy Here
  • Craft Knife or Scissors – Buy Here

How To Build Your Windowsill Greenhouse

To start off, you’ll need to assemble the frame. The frame is made up using kebab sticks. Two sticks placed length ways make up each vertical post with on placed horizontally for support.

greenhouse kebab support frame

In order to join the sticks, the sticks are split using a craft knife and slid into one and other. The numbers on the above sketch indicate the type of joints, these joints are shown up close below.

To optionally strengthen the joints, drip any kind of glue, like superglue all over the joint, and wrap thread or string around the joint, knotting it to keep it in place.

how to improve the joint strength

Finally, to complete your greenhouse, find a clear bag which is big enough to pull over your frame. If you can’t find a big enough bag, another option is to cut plastic sheeting or bags and glue them to the structure instead. Try to tuck the bag underneath the greenhouse to help seal it properly to keep heat/moisture in and pests out. The roof area of the greenhouse will be strong enough to allow a LED light to rest on top if you want to add light, but be sure that the temperature of the light stays cool so that it does not melt the plastic.

Now place your homemade greenhouse on a sunny windowsill, insert your favorite plants or veggies and watch them grow!

Have you tried to make your won mini greenhouse? Let us know your tips and tricks in the comments section below.

This post is based on No-Budget Windowsill Greenhouse by lsadwdwadw and has been modified and used under the Creative Commons license CC BY NC SA 2.5.

 

Upcycling Wood Pallets Into Furniture

Michael Klements
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0
Upcycling Wood Pallets Into Furniture

Have you got a couple of old pallets lying around or have you seen some stashed at your local grocery store? With some effort, you can easily turn an old pallet or two into stylish furniture and decor for your home. The guys at fix.com have some great ideas for your next upcycling pallet furniture project, have a look at some of their ideas below.

How To Prepare A Pallet For Your DIY Project

Pallets are great, but you have to make sure the wood isn’t chemically treated – especially if you’re building something like a raised vegetable garden bed. Also, ask someone if the pallet was used to haul hazardous materials. If so, stay away. But if it was hauling orange juice, furniture, or otherwise nontoxic items, you’re good to go.

Almost every project you do with pallets will require you to disassemble the pallet, remove nails, and sand down any rough edges. You’ll need a crowbar or pry bar, a hammer, and a power palm sander for these parts. This would also be a good time to give your boards a thorough cleaning with some basic soap-and-water solution.

how to prepare a pallet for your diy project

Projects You Can Build Using Wood Pallets

Build an Awesome Table

You can use pallets to create a whole bunch of different style tables from scratch, or you can use pallet wood to update some sad outdoor furniture.

If you’re building one from the ground up, you’ll probably want to pick up a few extra supplies for the legs and supports and stick to using your pallet wood for the table top. To create your table top, determine the dimensions of your table and cut your boards (if you need to) down to size.

Lay them down on a flat surface and secure them on the underside using two parallel 1” x 3” boards and strong, long wood screws.

For the table legs, you can go industrial chic and use piping from the hardware store, order some retro hairpin legs, or use 4” x 4” wood pieces to create a more traditional X-leg trestle table. Stain or paint the top if desired – just make sure you seal it well if it’s going to be used outdoors.

Create a Cool Rustic-Industrial-Style Desk

This might be one of my favorite ways to re-purpose a pallet, especially if you’re in an urban setting. The good news is if you want to make a cool pallet desk, you don’t have to disassemble the pallet!

First step is to decide on the depth of your desk. The typical depth for a small-space desk is anywhere from 17” to 22” deep. Using a level, draw a line down your pallet at your chosen measurement and then cut straight through both pallet layers with a circular saw.

Using the wood left from the smaller piece, create a wall brace about 4” below your ideal desk height. Secure it to the wall using screws driven into the wall studs.

Next, you’ll want to add legs to the front of your pallet desk. I definitely recommend those cool hairpin legs for this project.

Place the back of your desk over your secured wall support and attach it using wood screws.

Boost Your Wall Storage

Often, if you tweak a pallet just a tiny bit, it can be used for awesome wall storage in all areas of the home.

boost your wall storage with wood pallets

A smaller pallet can be painted or stained in fun colors, mounted to the wall using screws into studs, and then used as book storage in a playroom or kids’ room.

Use the same basic principle in the kitchen or dining room but, instead of books, use the pallet to store large or long serving dishes. Add small hooks to the front of the pallet for visual interest and to display pretty tea towels or even coffee mugs.

Now head to the shed or garage! Hang a few pallets on the wall side-by-side and make sure they are level with the floor. Paint them a fun color if desired. Now add all your long and awkward lawn care tools! Rakes, brooms, garden hoes, and more will all stand propped up in your new vertical storage unit. Add hooks or baskets to the front of the pallets for your smaller garden essentials such as spades and gardening gloves.

Amp up Your Foyer With Pallet Bench and Shoe Storage

If you hit the motherlode and find a bevy of free pallets, this might be the right project for you. Just like with the wall desk, you’ll want to first determine the depth you’d like your combination bench-shoe storage cabinet to be. Make sure it doesn’t overtake your whole front-door area, but also ensure that it will be deep enough to sit on comfortably – 18” is probably a nice place to start for depth.

Foyer Wood Pallet Storage And Bench

Use a circular saw to cut down your sanded and cleaned pallets to 18”, but do not discard the leftover wood!

This is the stage where you’ll want to paint or stain the pallets your desired color. Once they are dry, place one 18” pallet on top of another and secure with wood screws. Keep stacking and securing your pieces together. Once all your pallet pieces are stacked, cut down the leftover pallet boards to match the depth of your bench and use them to plank the top of your bench.

Stain the top the same color or a different color for added interest! Your shoes will sit in the pallet slats! Add a pillow for comfort and some coat hooks above your bench and you’ll have a stylish, rustic, DIY entryway solution.

Looking for some more creative pallet ideas? Here are another 8 creative pallet projects for you to try out. You could also try making these mini pallets as coasters or gift packaging.

As you can see, there are a ton of ways to use pallets in your home, both indoors and outdoors. Next time you’re out and about, keep your eyes peeled and your creativity dial turned up and you might just find yourself the proud owner of something DIY and fabulous.

Let us know in the comments below if you’re tried any of these or other projects involving upcycling wooden pallets in your home! If you’re looking for more project ideas, have a look at fix.com, they have a great range of projects and home improvement ideas for you to try.

3D Print Surface Finishing Techniques, Get A Smooth Surface Finish

Michael Klements
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0
3D Print Surface Finishing Techniques, Get A Smooth Surface Finish

3D Printing is great for producing cheap customised plastic parts, however, the surface finish is usually quite rough due to the rounded plastic extrusion building up each layer. Here are some techniques which can be used to produce a smooth surface which can then be painted to produce a professional looking part.

What You’ll Need To Get A Smooth Surface Finish

  • Sandpaper – 100, 180 and 320 grit
  • Polyester body filler or putty
  • Plastic Primer
  • Spray Paint

3D Print Surface Finishing Techniques

Start out by sanding the piece with the 100 grit sandpaper for 5-10 minutes.

start off by sanding the 3d print

Then do the same thing but with the 180 grit sandpaper and after that, repeat the same step but with the 320 grit sandpaper. By sanding you will give your piece smooth surfaces without any imperfections or excess plastic.

If you happen to damage an edge or corner then don’t worry, you’re piece isn’t ruined yet. You can fix any imperfections easily with polyester potty.

First, take the piece of wood and mix the polyester putty.

prepare your putty

Take the plastic piece that came with your polyester putty and scoop a little bit and spread it on the damaged edge or corner. Don’t be afraid to put a lot of putty on the damaged part, the more putty the better.

apply the putty

Repeat the sanding steps starting from the course grit and working to the fine grit after the putty has dried.

sand the putty down

You are now ready to paint the object. In order to get good paint adhesion we will have to spray primer made for plastic surfaces on the piece we’re working on.

Clean the surface with a brush to remove any dust that may be left on the piece.

Some tips to avoid dripping:

– Spray carefully in strokes from left to right

– After applying one layer, wait 30 minutes until the primer is dry

apply the primer

Now apply the spray paint. Give the piece a couple of layers until you reach the result you desire.

apply the spray paint

You can also use putty to fill voids in a 3D printed shape.

using putty to fill voids in 3d printed shapes

Apply a coat of paint to cover up the body filler.

apply spray paint

Now you’re able to 3D print models and get a professional surface finish. Do you have any tips and tricks for finishing off your 3D printed models? Let us know in the comments section below.

This post is based on 3D Surface Finishing Techniques  by robrechtv and has been used and modified under the Creative Commons license CC BY NC SA version 2.5.

How To Get Rid Of Mould On Your Ceiling

Michael Klements
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0
How To Get Rid Of Mould On Your Ceiling

Mould developing on your bathroom or kitchen ceiling is generally as a result of poor ventilation. Steam and water vapour get trapped in the bathroom and eventually condense on the ceiling causing a damp spot which is perfect for the growth of mould and bacteria. You should try to treat patches as soon as they appear as the longer they have to grow, the larger the patch that needs to be cleaned and the more difficult it is to get rid of it. If you leave it too long, you may even have to replace a portion of your ceiling board.

A patch on your ceiling may also be as a result of a leak in the ceiling or walls above. It is worth checking the area in the ceiling above the mould spot for possible leaks.

What You Need To Get Rid Of Mould On Your Ceiling

  • Paint Scraper
  • Household Bleach or Hydrogen Peroxide
  • Spray Bottle
  • Scrubbing Brush
  • Gloves & Safety Glasses
  • A Ladder

How To Remove Mould From Your Ceiling

Before treating the mould, open all of the doors and windows to allow adequate ventilation. If you have wallpaper or polystyrene crown moulding near the area to be treated, cover this up with plastic sheeting before working near it so that you don’t damage it with the bleach or peroxide solution.

Scrape away any loose or flaking paint and mould.

If you are using bleach, dilute it with five parts water and put it into the spray bottle. Hydrogen peroxide can be used neat. Spray the solution directly onto the mould patch on the ceiling and allow it to work for 10 minutes.

how to get rid of mould on the ceiling

Scrub the area lightly with your brush, rinsing the brush occasionally to prevent the mould from spreading and discolouring the surrounding area.

Once your have worked away all of the loose bits, repeat by spraying the area and allowing it to stand for 10 minutes again before re-scrubbing. These steps should be repeated until the mould has all been removed.

The ceiling may require a fresh coat of paint once you have finished cleaning the mould in order to cover up any discoloured areas. High cover primer is usually the best for covering up stains on white ceilings, apply one or two coats, allowing drying time between coats.

Preventing Mould In Future

Now that you have finished cleaning and restoring your ceiling, you need to look at preventing it from growing back again. The most likely cause is poor ventilation, keep the windows and doors open for a few minutes after using the bath or shower to allow the steam and moisture to escape. If you don’t have windows or they are too small to open, consider installing a small extractor fan to assist with removing the moisture.

Have you managed to restore a section of your ceiling? Let us know your tips and tricks in the comments section below.

Dust is another health hazard in your home, have a look at our 5 Cleaning Tips To Rid Your Home Of Dust.

How To Repair A Chip In Your Windshield

Michael Klements
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5
How To Repair A Chip In Your Windshield

If you have a chip in your windshield, it is necessary that you get it repaired as soon as possible. A small chip in your windshield can turn into a big crack quite quickly. After the first layer of your windshield is penetrated, it is likely to crack out causing further damage and the need for a costly replacement. Repairing your windshield when you notice a chip will save you money in the long run. You can call a windshield repair company, or do it yourself. They usually sell inexpensive windshield repair kits at your local auto parts store.

What You’ll Need To Repair A Chip Or Crack In Your Windshield

You can purchase a windshield repair kit (such as this one) from your local auto parts store, which will include all the necessary tools and supplies.

  • A Mirror to Place on the Inside of the Glass
  • A Bridge & Injector
  • Repair Resin
  • Pit Filler
  • Plastic Curing Tab
  • Razor Blade

How To Repair The Windshield Chip Or Crack

The first step is to prep the chip and windshield for repair, use an alcohol pad to clean the area, and gently scribe out any loose glass from the “impact point”.

Next, hook your mirror up on the inside of the windshield, centered on the chip you are going to be repairing. This will allow you to keep an eye on the chip from all angles, which is very helpful with all glass repairs.

windshield chip or crack repair mirror

You want to center your bridge or whatever tool you are using directly on the chip. You basically want to create a seal over the area of the chip that is missing glass.

position your injector over the chip or crack

After you effectively have created a seal around the chip, put 3-8 drops of resin into the injector area.

put drops of resin into the injector

Next, Use the injector to push the resin into the chip. You should be able to see it start to clear up through your mirror. Keep an eye on it, releasing air and re-injecting the resin when needed. Leave it alone for about 5-10 minutes.

inject the resin into the crack

Be sure to keep the area covered if you are in direct sunlight, as you do not want the resin to cure prematurely.

After you have let it sit, and it appears as if the chip has cleared up, you can remove the bridge.

The repair is just about complete, but we still need to fill in the “pit” of the chip. The pit is the area where little bits of glass are missing. This step will give the glass a smooth finish once again. Get your pit filler, and drop a tiny bit directly on the impact point. Grab a plastic curing tab, and place over the area. Leave alone in direct sunlight for a minute or so to let it cure.

filling the chip pit

Grab a razor blade, and hold it securely upright. Scrape off all excess pit filler, leaving only the area where glass was missing filled.

clean up the surface of the chip

You can even go an extra step and use a light polish on the area to be sure that the area is flush.

Cosmetically windshield repairs clear up anywhere from 30%-80% depending on many variables. Age, Moisture, dirt, location, and temperature all play a roll in the appearance of a repaired chip. Structurally, the glass should be back up to 100%.

Have you tried repairing a chip or crack in your own windshield? Let us know your tips and tricks in the comments section below.

This post is based on How to Repair Your Windshield by Austin Windshield Repair (view original here) and has been modified and used under the Creative Commons license CC BY NC SA.

Make Your Own 3D Printed Dremel-Style Rotary Tool

Michael Klements
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0
Make Your Own 3D Printed Dremel-Style Rotary Tool

There are plenty of DIY Dremel-style rotary tool ideas available on the internet but there isn’t really anything that is powerful enough or usable in the long term, while still looking good! So here are plans to make your own 3D Printed Dremel-style rotary tool which is compact and light, yet powerful enough for 90% of the things you’ll need to do and makes much less noise than commercial ones.

dremel style rotary tool 3d cad design

The design was done by Makernaut who used Fusion 360 for the 3D CAD model. The front part has a groove for more control while doing detailed work. It has a snap fit which makes it detachable for changing tool bits. The rest of the casing is made up of 2 parts stuck together using adhesive and holds the motor and pcb with ventilation holes for cooling.

What You’ll Need To Build Your Own Dremel-Style Rotary Tool

  • 3D Printer or 3D Printed Parts
  • 12V DC Motor: Listed as 6000 rpm, RS-550S Motor. Diameter~37mm – Buy Here
  • PWM DC Motor Controller 3A – Buy Here
  • Mini Chuck/Collet Set for 3.17mm Shaft – Buy Here
  • Adhesive – Buy Here
  • Wires
  • Black Rubberized Automotive Paint(Optional) – Buy Here
  • 12V Power Supply , At Least 5A Current – Buy Here
  • Rotary Tool Bits – Buy Here

How To Make Your Dremel-Style Rotary Tool

3D Print The Casing

To start off with, you’ll need to print the 3 parts which make up the casing. You can either print these using your own 3D printer or use a printing service such as 3D Hubs.

Here are the 3D print models:

Front

Lower Casing

Upper Casing

The parts should be printed with PLA with a 0.2mm layer height.

Assemble The Components

Sand and Finish the parts to get the right fit and remove irregularities. Especially the snap fit at the front cover. You could also temporarily connect the motor to a 12V battery and chuck, and use the tool bit for sanding.

sand the components to get the right fit

Don’t forget to wear appropriate safety equipment.

After sanding and finishing, Paint the lower-part with Black Rubber Automotive Paint for a nice grip and aesthetics. Apply 4 coats for a nice soft-touch feel. Paint outside in open area and use safety gear.

paint the bottom cover

Solder the wires to motor terminals, the other ends go to the ‘Motor +/-’ terminals on the PWM controller circuit board.

Pass 2 wires through the smaller hole at the end of the ‘lower-part’ and through the small triangular hook as shown in image. Then connect one end to the ‘Power +/-’ terminals on the circuit board and other end to a 12V power supply.

connect the wires to the motor

Turn on the 12V supply to ensure that the motor turns counter-clockwise. If not, switch the wires going into ‘Motor +/-’ terminals.

Using 2 machine screws provided with the motor (usually M3 screws), secure the motor to the front side of the casing.

screw the motor to the casing

Remove the potentiometer cap from the PWM controller and insert it through the hole at the end of the lower casing. Using a minimum of two M3 self tapping screws, secure the PWM controller board to the lower casing.

Tuck the motor wires in, and stick the lower casing to the other half casing by applying adhesive at the edges.

glue the two hlaves together

Insert the chuck on the motor shaft and secure it. Snap on the front plastic cover. Put the potentiometer cap back on.

add the chuck to the front

Your Rotary Tool Is Now Ready To Use

Cut, Engrave, Sand, Polish, Drill many materials including most Plastics, Woods, relatively Soft Metals like Aluminium.

Smaller tool bits fit in directly, but for larger bits either you may sand the opening hole of the front cover or not use the front cover. The front cover is mostly for holding the rotary tool closer to the tool bits to give more control.

Have you tried making your own rotary tool? Let us know in the comments section below!

This post is based on 3d Printed DIY Dremel-style Rotary Tool by Makernaut and is modified and used under the Creative Commons license CC BY NC SA.

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