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July, 2010

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Make Your Own Turbine Jet Engine (And Then Put It In Your Porsche)

Friday, July 30th, 2010

Four cylinder Honda Civic Hatchback doesn’t have enough “get-up-and-go” for your tastes? Maybe it’s time to upgrade to a Steve Saunders-esque V8 Corvette. Or maybe you want to drop some serious cash and get the 16 cylinder Veyron (with its four turbochargers). But no matter how many cylinders it has, your car won’t ever be as cool as one powered by a turbine jet engine.

Typically thought of for airplanes, helicopters, locomotives and army tanks, turbine engines have some interesting advantages over internal combustion: lower weight, increased horsepower and torque, and you can feed them almost anything – the ones I’ve played with were filled with kerosene, diesel, and anything else highly flammable we could find in the garage. They’re reasonably simple machines, mechanically less complicated than a car’s gas engine. But they also come with an hefty thirst, and generate crazy amounts of heat.

For the past ten years, Michael Davis has been building his own turbine jets from parts that he sources online and in junkyards. Based around a standard automotive turbocharger, Davis spent about $150 and four months to get his first unit up and running. His site follows all the trials and errors of building a jet engine this way, and serves as a good guide for anyone interested in playing with loud, powerful jets in their back yard.

Combine his site with this Instructable about building your own jet engine and you should have the full recipe for putting together the ultimate noisemaker.

Now, the fun part. Back in the early 1960′s, Chrysler focused a lot of resources on creating a viable turbine jet engine car. The high point of their push was in 1963 when they released 50 cars to a group of “average” people for real world testing. The results were good, and according to the car’s wikipedia page, the cars logged 1.1million miles over the testing phase and only had 4% downtime. But, hilariously, they were described as sounding like giant vacuum cleaners, a negative point that helped kill the program. Ultimately and unfortunately, the whole program died during the government bail out in the 1970s.

Chrysler also produced a promotional video for the turbine program in classic early-60′s style. Check out the proving grounds they test their cars on – that’s an unusual amount of winding dirt trails for your “average” Chrysler driver, right? If it still exists, I would love to bring a few cars there to test out myself.

Other turbine engine cars pop up from time to time, most recently a few weeks ago on eBay when someone was unloading a Boeing T-50 powered Porsche 928. Complete with flame throwers from the hood of the car. As my pal Steve commented, you have to wonder how long you can drive that thing until the windshield melts… Regardless, it sold for $12,000 – although it was originally listed at $20k.

1982 PORSCHE 928 WITH A BOEING TURBINE ENGINE

TURBINE ENGINES RUN FINE ON DIESEL

POWER STEERING

POWER DISK BRAKES ALL 4

HEATER AND DEF….(BLEED AIR TO HEATER CORE)

NEW PAINT

NEW WHEELS 18″

JVC FM AND CD PLAYER WITH REMOTE

FLAME SHOOTER

17 MPG

OVER 160 MPH

365 HP

700+ FOOT POUNDS OF TORQUE

IT’S A DAILY DRIVER AND A SHOW CAR

USE TO BE NEW

AT LAST AN AIR COOLED 928

How to Pirate A Vinyl Record, And How Vinyl Records Are Made

Wednesday, July 28th, 2010

Vinyl records have a unique place in the world of music media. Aside from their warm analog tone, vinyl is the only popular medium that is nearly impossible to create or duplicate at home – something that can’t be claimed by cassettes, CDs, DVDs, and certainly not mp3s. Not to be an apologist for piracy, this inherently creates more value for recorded music than using an easily reproducible medium (be it physically or digitally) does. But as we all know, digital is the present and the future, and I am not complaining about that at all; one look at my iTunes playlist and you’ll know what I mean.

A while back, the site qj.net ran a piece on how to “pirate” a vinyl record using normal silicone casting materials. Sadly, the link is broken, but thanks to the Wayback Machine, I’ve pulled the archived copy up and am attaching it here for posterity:

Posted May 14, 2006 at 06:49AM by Anna S.Listed in: Misc. Gadgets

So you thought you’ve pirated everything huh?

Step 1

Using the wooden strips, make a box around the glass plate. Seal off the edges using the window cement. Make sure everything is air tight.

Step 2

Place your record inside the box making sure that the portion to be copied is facing upward. Squeeze in some window cement to mark where the hole in the record is.

Step 3

Mix the silicone (Smooth On OOMOO 30 or OOMOO 25) for about 3 minutes before pouring in to the mold.

Step 4

Pour in the mixture. Start from one corner and let it fill-up the mold to about half a centimeter. Make sure it’s even. Let it dry for 6 hours.

Step 5

Peel off the silicone from the cast. Cut off the excess using a cutter.

Step 6

Pour the liquid plastic (Smooth On Task #4) on top of the silicone cast.

Step 7

Make sure that nothing spills over the round form. You can also brush off any air bubbles that might occur.

Step 8

Carefully loosen the plate from the silicone form. Using a drill press, bore a hole through the center of the plate. You can use the silicone form as a template to make more copies.

There you have it. Your very own pirated record.

(QJ translated this from the German site Zeit.de, also unavailable except via archive)

How well does this work? To be seen… the next step is to rip a vinyl record (pretty easy to do using a USB turntable), then cast a copy of it using this technique. Rip the copy, compare waveforms and look for any major discrepancies. That’s an upcoming project.

==========

Now, if you haven’t seen the exact process in how records are created, you might be surprised at how much manual cooperation is involved. From inspecting the metal pressing discs and the lacquered masters, to centering the disc for hole punching, you’ve got sweet old ladies who are meticulously making sure your music will sound great. And the actual assembly process, even with automation, is like something you’d see in a Detroit auto maker’s factory: heavy hydraulic equipment pressing hot platters into precision shapes, rotating slicers, and vacuum-assisted label placers.

You can watch the whole process happen, courtesy of Discovery’s “How It’s Made” – part two is where things get interesting.

Anodize Aluminum at Home with Everyday Materials

Thursday, July 22nd, 2010

Anodizing is a process that builds up a very thin but strong protective layer on the surface of a non-ferrous metal. It is achieved using chemical/electrical oxidization, and is most commonly done on aluminum , but occasionally also seen on titanium, silver and other metals. If you’ve ever seen one of those blue or red Maglite flashlights (and I’m sure you have), you’ve seen anodized aluminum. The color comes from dyes that are used after the anodizing process to give it color before sealing the surface layer tightly.

Although aluminum anodizing is often done for large-scale commercial uses, the process is reproducible for smaller home-brew projects using easy to find chemicals and containers (like plastic coolers). The best set of DIY instructions around come from Ron Newman – he has a detailed breakdown of each step, and even sells the solutions and kits to get you started. Here’s a simple overview:

• Soak aluminum part in cleaning solution
• Etch part in caustic lye solution
• Desmut (done if etched or for certain aluminum alloys)
• Connect part to positive electrode of power source, with cathode (negative electrode) submersed in anodizing solution. Submerse for one hour.
• Dye
• Seal part using nickel acetate sealer

Of all the steps, the most involved is setting up the power supply to charge the solution and cause the anodizing process to occur. A battery charger is a simple tool that can work here, although Newman’s writeup says to use a somewhat pricey rectifier to help control the current to the proper level to get decent results. Other anodizing pages such as from Steve Mass and Bryan Pryor suggest that the battery charger can be difficult to monitor and control – they prefer using a dedicated DC power supply instead.

Caswell plating sells supplies for anodizing – check with them for materials.

Computer-choppers.com offers custom anodized Mac Mini cases.

 

On a larger, industrial scale, full factories are used to anodize oversized pieces of metal for building purposes. The general process is the same though.

Now, lets say you need to remove the anodizing for some reason or other (perhaps you don’t want your paintball gun to look like a pink and blue easter egg anymore). The system is pretty straightforward:

You can strip off the existing anodized layer from any anodized part by placing the part in a caustic solution for an hour or so.  Just mix a few tablespoons of lye and water in a plastic container.  Wear eye protection and rubber gloves for this procedure!!  Place the part in the solution and monitor its progress.

The Lye will dissolve the old anodized layer, about .001″ thick.  It takes a while for it to start breaking through the layer.  It’s a little slow at first.  The first ten minutes or so not much action will be seen.  Bubbles and smut will rise up as an indicator of its progress.

Or, you can use a parts washer like this video shows:

And, as mentioned above, you can use this technique on other metal types. Here’s a demonstration of anodizing a bar of silver:

Finally, one more page with a full rundown on the anodizing process: DIY aluminum anodizing

Now, go anodize some stuff! Car parts, bike parts, water bottles, pizza peels. Let your imagination run wild, just like the wild colors you can use.

Guitarist and Musician Project: Make Your Own Digital Delay Pedal

Thursday, July 15th, 2010

This is a low-cost, easy to follow project that appeals to all of us who have wanted to sound like a guitar god at some point. Delay pedals are a staple effect of so many musicians these days. Take U2′s The Edge; his sound is almost entirely based on the use of delay.

The Instructable for this project goes light on the actual electronics, but fortunately many more detailed writeups exist already. The case for it gets more attention, and you can tell – it looks professional.

One note that is made in this interesting piece by RG Keen on the economics of pedal building – if you’re doing this to try to save money, don’t. Cheap delay and effects pedals can be bought new for as low as $20 – and used for even less. But there is a real value in building something yourself, so make sure to calculate that aspect in as you prepare yourself to embark on this project.

My schematic is largely (read: almost entirely) based upon Casper Electronics’ EchoBender pedal, which is in turn largely based on Tonepad’s Rebote 2.5 Delay pedal, which is in turn, more or less, based upon the example schematic in the PT2399 datasheet. Having breadboard all three, I personally can not hear a significant difference in sound between the Casper Electronic version and the one on Tonepad, which some people say is superior sounding (the one in the datasheet just sounds flat). The nice thing about the Casper Electronics version is the inclusion of a feedback pot, which gives a really full sound to the echo effect.

You will need:
(x1) “BB”- sized Steel Enclosure
(x1) PT2399 Echo Processor
(x1) TL072 low noise op amp
(x1) LM7805
(x3) 100K potentiometers
(x1) 50K potentiometer
(x1) 5K potentiometer
(x1) PCB
(x1) DPDT stomp switch
(x1) SPST toggle switch (SPDT okay)
(x1) Power jack (with cut-off)
(x2) 1/4″ mono jacks
(x5) Knobs
(x1) sheet 1/16″ santoprene rubber (McMaster-Carr 86215K22)
(x1) sheet 1/8″ cork

capacitors:
(x1) 100uF
(x3) 47uF
(x1) 4.7 uF
(x6) 1 uF
(x3) 0.1 uF
(x2) 0.082 uF
(x3) 0.0027 uF
(x2) 0.01 uF
(x1) 100 pF
(x1) 5 pF

resistors:
(x2) 1K
(x11) 10K
(x2) 15K
(x1) 100K
(x1) 510K
(x2) 1M

Recipe Video: Cooking Koshari – Delicious Egyptian Vegetarian Dish

Thursday, July 8th, 2010

Koshari is a traditional dish from Egypt, one that tastes so good I can’t stop eating until nothing is left. The dish has many parts, all of which are pretty simple but combine together for complete deliciousness: Rice/lentil (referred to as koshari), spicy tomato sauce, macaroni, garbanzo beans and fried onion.

Here is the recipe to make the best tasting koshari I’ve had so far. I’ve based the approximate measurements off of the video I took of Magda and Sandra demonstrating how to cook the dish (very special thanks to both of them for taking the time to let me film this and feeding me).

Ingredients:
Koshari:
1 large yellow onion, chopped
1/2 cup corn oil
1lb lentil beans
2 cups basmati rice
4 cups water
1 tablespoon plain tomato sauce
1 glove of garlic, crushed

Sauce:
(2) 16oz cans  of tomato sauce (video says 6oz – was meant to say 16oz)
1 tablespoon corn oil
5 cloves of garlic, crushed
1 teaspoon salt
1 teaspoon pepper
1/2 teaspoon cinammon
2 tablespoon white vinegar
1 green chili pepper or 1/2 teaspoon red pepper flakes (optional)

Pasta:
1lb macaroni, small size (elbows)
1 teaspoon salt
1 teaspoon pepper

Garbanzos (topping):
1 can garbanzos, drained and rinsed
1 teaspoon salt
1 teaspoon pepper
1 teaspoon cumin
1 teaspoon garlic pepper
1 tablespoon lemon juice

Instructions:
Koshari:
- Begin by soaking the lentils and rice in water for about 30 minutes (separately). You don’t want the lentils to get too soft, so don’t over-soak them.
- Chop the onion coarsely – about 1/2″ squares. Put in large stock pot, add corn oil so the onion is covered. For one onion, this was about 1/2 cup.
- Heat on medium-high, stirring regularly. Cook until darkish brown, about 15-20 minutes. Watch closely as the onion goes from dark brown to burnt very quickly.
- When finished, remove onion from stock pot with slotted or perforated spoon. Place onion on paper towel to drain. Keep oil in pot.
- Add one clove crushed garlic to the oil.
- Stir in four cups of water and one tablespoon of tomato sauce.
- Add lentils when the water begins to boil, cover and cook until lentils start to soften (about 20 minutes).
- Once lentils soften a touch, stir in rice, cover, and continue to heat.
- Finished once water is soaked up and the lentil/rice mixture is soft and fluffy.

Sauce:
- Crush five cloves of garlic, put into saucepan with a tablespoon of corn oil.
- Heat on stove, medium-high.
- Add 1 to two tablespoons of white vinegar and two 16oz cans of plain tomato sauce.
- Thin sauce with 1/4 to 1/2 cup of water.
- Pinch of salt, pepper and cinnamon to the sauce.
- Chop a green pepper and add to the sauce, or use red chili flakes
- Cover, bring to a boil, then reduce heat and let simmer for 20 minutes

Pasta:
- Boil water in large pain
- Add one pound small macaroni shape. Elbows work well.
- Cook slightly longer than the directions call for – you want the pasta to be soft.

Garbanzos:
- Drain and rinse a can of garbanzo beans (chickpeas)
- Mix in salt, pepper, cumin, garlic powder
- Sprinkle with lemon juice

Prepare by making a bed of the rice and lentils, add macaroni on top, coat with sauce (the sauce is my favorite part – that vinegar/cinnamon addition makes it so tangy-good), top with garbanzos and fried onions. Serve with a nice cucumber and tomato side salad.

Serves six. Or one, if I’m there.