Category Archives: machining

DIY Electric Roller Bender Can Handle The Thick(er) Stuff

Every serious metal worker will end up getting themself a roller bender at some point, but if you’re as dedicated as [Meanwhile in the Garage], you might just start building the things yourself. His heavy-duty electric roller bender, demonstrated in the video after the break, is perfect for the thicker …read more

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Posted in bar bending, bending, machining, metalworking, tool hacks, welding | Leave a comment

Restoring a Rusty Rebar Cutter

We’ve all probably come across hunks of junk that used to be tools, long-neglected and chemically welded into a useless mass of solid rust. Such items are available for a pittance at the local flea market, or more likely found in an old barn or rotting on a junk pile. …read more

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Posted in compound, cutter, leverage, machining, metalwork, rebar, repair, repair hacks, restoration, teardown, tool, tool hacks | Leave a comment

How To Make an Electric Scooter Chain Sprocket With Nothing But Hand Tools

Sometimes, mechanical parts can be supremely expensive, or totally unavailable. In those cases, there’s just one option — make it yourself. It was this very situation in which I found myself. My electric scooter had been ever so slightly bested by a faster competitor, and I needed redemption. A gearing …read more

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Posted in chain drive, chain sprocket, fabrication, Hackaday Columns, machining, scooter, scooter hacking, sprocket, sprockets, transportation hacks | Leave a comment

DIY Tiny Dovetail Cube Needs DIY Dovetail Cutter

There’s a trinket called a dovetail cube, and [mitxela] thought it would make a fine birthday present. As you can see from the image, he was successful in creating a tiny version out of aluminum and brass. That’s not to say there weren’t challenges in the process, and doing it …read more

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Posted in aluminum, art, brass, dovetail, dovetail cube, freestyle, machining, tool hacks | Leave a comment

Finely Machined Valve Controls Miniature RC Hydraulics

Hydraulic components are the industrial power transmission version of LEGO. Pumps, cylinders, valves – pretty much everything is standardized, and fitting out a working system is a matter of picking the right parts and just plumbing everything together. That’s fine if you want to build an excavator or a dump …read more

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Posted in cylinder, hydraulics, machining, misc hacks, proportional, rotary, spool, valve | Leave a comment

[Ben Krasnow] Drills Really Small Holes with Electricity

Drilling holes is easy; humans have been doing it in one form or another for almost 40,000 years. Drilling really tiny holes in hard materials is more challenging, but still doable. Drilling deep, straight holes in hard materials is another thing altogether.

Luckily, these days we have electric discharge machining …read more

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Posted in arc, cnc, cnc hacks, drill, EDM, electric discharge machining, machining, metalwork, tool hacks | Leave a comment

Creating Lenses On Cheap CNC Machines

There are a lot of CNC machines sitting around in basements and garages, but we haven’t seen anything like this. It’s making lenses using a standard CNC machine and a lot of elbow grease.

The process of making a lens with a CNC machine begins by surfacing a waste board …read more

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Posted in cnc, cnc hacks, lens, machining | Leave a comment

Radio Control Buggy Gets V10 Power

Amongst the more difficult machining tasks in the world are those involved in the production of internal combustion engines. Thanks to the Internet, it’s now possible to watch detailed videos of master craftsmen assembling tiny desktop V8 and V12 engines in home workshops with barely a CNC in sight. However, up until now, most of these builds have been left on the test stand to bark and wail away. No longer – [Keith] has decided that needs to change.

We’ve seen [Keith]’s work before – particularly, his 125cc V10 build, featuring fuel injection, dual overhead cams, and even a supercharger. …read more

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Posted in buggy, Engine Hacks, machining, model engine, radio control, rc, supercharger, V10 | Leave a comment

A Three Axis Mill For The End Of The World

A mill is one of those things that many hackers want, but unfortunately few get their hands on. Even a low-end mill that can barely rattle its way through a straight cut in a piece of aluminum is likely to cost more than all the other gear on your bench. A good one? Don’t even ask. So if something halfway decent is out of your price range, you might as well throw caution to the wind and build one.

That’s more or less the goal behind this extremely basic three axis mill built by [Michael Langeder]. Designed around a cheap …read more

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Posted in cross slide vice, hardware, junk bin, machining, metalworking, mill, tool hacks | Leave a comment

Super Magnesium: Lighter Than Aluminum, Cheaper Than Carbon Fiber

We think of high tech materials as the purview of the space program, or of high-performance aircraft. But there are other niche applications that foster super materials, for example the world of cycling. Magnesium is one such material as it is strong and light, but it has the annoying property of burning in its pure state. Alloys of magnesium meanwhile generally don’t combust unless they are ground fine or exposed to high temperatures. Allite is introducing a new line known as “super magnesium” which is in reality three distinct alloys that they claim are 30% lighter than aluminum, as well …read more

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Posted in machining, magnesium, parts | Leave a comment