My vice is a vise

My YouTube feed got bombarded with vise restoration videos last fall. I’ve been using a Harbor Freight vise in the interim that worked fine enough but I felt it just didn’t have that panache that an old school heavy duty vise would bring to the shop. I was on the lookout for a vise to make my own.

I happened to be chatting with my Dad on the phone while he was visiting the Jacktown Engine show in Bangor, Pa and on a whim I asked him to be on the lookout for a vise for me. No longer than two minutes later he called me back to say he stumbled upon 3 chunky vices for sale. We agreed to get the largest – A Charles Parker No. 974.

I selected the vice in the middle a Charles Parker 974 from the Jacktown Engine show.
Charles Parker 974 restoration
The Charles Parker Vise No. 974 disassembled

The vise was solid, but cosmetically it needed a lot work. It was mostly covered with hard caked grease, rust, and remnants of paint. I disassembled the entire vise which wasn’t too hard to accomplish. I was happy I didn’t have to mess with any caustic paint remover and I buffed off the majority of the surface scale with a wire wheel on my bench grinder. I moved in and hit the nooks and crevasses with a cup wire wheel on my angle grinder.

The first coating of primer

I used a spray paint rattle can of grey primer and put on a final coat of blue enamel spray paint and hit it with a final coat of clear coat.

I used a white paint pen to trace the raised letters. This part of the restoration is most pleasurable!

The refurbished Chas. Parker Vise No. 974
Charles Parker 974 refurbished

Final thoughts

Before the refurbishment, this chunk of metal was just a vise that I owned, after the final painting and assembly it became “my vise”. The entire process turned out to be much easier than I had expected and anyone with a wire wheel, patience, and some elbow grease can refurbish a rusty old vise into a shop gem. My only complaint is the Charles Parker vise jaws are a very unique design and don’t readily lend themselves to easy customization or replacement. I was fortunate the jaws on this model are ina satisfactory state. Other than that the Charles Parker vise is a majestic relic of the American industrial era.

I’d like to try my hand at refurbishing a Reed vise next.

Socket wrench tool holder

Socket wrench tool holder
3d printed socket head ratchet holder on Prusa i3Mk3s

Tonight I finally scratched a big itch of mine to design a quick lift and go tool holder for my drive ratchet set. I had a good idea in my head how I wanted it to work. It didn’t take too long to model it. I was very pleased with my first prototype. The color of the bright metallic blue of this ProtoPasta filament I’ve recently switched over to looks brilliant and is remarkably sturdy. I NEED to try some of the Neon yellow of this type of filament!!!

3D printing my way to organization

Make: Electronics

COVID-19 quarantine continues and the extended time at home has presented another opportunity to pursue another passion project – performing every experiment in the Make: Electronics book, cover to cover with my children.

Make: Electronics
Learning by Discovery by Charles Platt

I didn’t want to piecemeal acquire the parts and potentially have any delays when we got started. The quarantine has noticeably exacerbated shipping delays. When we got started I wanted to be able to stream roll through the book. The second edition has a checklist appendix of all the supplies required and I purchased them all on amazon.com piecemeal in one fell swoop. (I know there are kits out there for this book, but I wanted to get lots of spares so both children could work simultaneously under my tutelage. You can never have enough LEDs, am I right?

Make: Electronics – the components acquired piecemeal via amazon

Make: Electronics Chapter 1

Experiment 1: Taste The Power

The kids were amazed at the tingle on their tongues! We were off to a good start

Experiment 2: Let’s abuse a Battery

This was a good experiment to discuss the concept of short circuits and the engineering reason for having a fuse in a circuit as an electrical safety feature. I had a leftover spare 3 amp circuit in hand that we used for the experiment. The children again were amazed how hot the wires and batteries got for this experiment. It was exciting to see the fuse blow under real-time observation.

Experiment 3: Your First Circuit

We opened up my old resistors and they had become jumbled and to my dismay the packs were not labeled. This was the perfect opportunity to introduce the multimeter and take the time to measure and label the resistance of each pack. It took a while to execute but the children were pros at this activity at the end.

The children were tasked with measuring and labeling all of the resistance values.

After the values were all measured and the resistor packs were sorted by least ohms to largest ohms we made our first battery-resistor-led circuit. We started with the largest value resistor which produced no light and then decreased the value which demonstrated an increasingly brighter LED.

Experiment 4: Varying the Voltage

Experiment 4: Varying the Voltage

With the concept of resistors mastered from the previous experiment, it was relatively easy for the children to grasp the concept of a potentiometer varying resistance as evidenced by the dimming LED with the turn of the knob. I admit – in a 2020 digital world there is something so gratifying about the smooth velvety feel of the analog knob of the potentiometer. Velvety smooth!

Experiment 4: Varying the Voltage

Experiment 5: Let’s Make a Battery

We didn’t have much success with this experiment. We got some voltage out of our setup but not much and not enough to light an LED. I don’t think we had enough fresh lemons and we substituted what I believe were galvanized washers in place of the galvanized metal plates, so perhaps one of these elements was a contributing factor.

Conclusions

Make: Electronics Chapter 1 was complete! The children were able to use a multimeter, understand the concept of voltage, current, and resistance. They built their first circuits, made LEDs light up and dim, and explored the use of a potentiometer. We were off to a good start!

A Light Emitting Diode (LED)

Prusa I3 Mk3S Upgrades

Now that I have had my Prusa I3 MK3S 3d printer for 4 months I have had an educational time upgrading the unit with aftermarket add-ons promoted by the 3d printing community. Obviously, one of the neatest aspects of the unit is that it can print it’s own upgrades!

Modified Duct Fan

Prusa Delta P Duct Fan Upgrade

The stock shroud that comes with the base kit was flimsy and chunks were occasionally meting off and falling in my prints. I stumbled upon the Delta P duct fan upgrade in a Reddit post. You can download the info and plans here. At the start I printed it and installed this fan configuration because I thought it simply looked really cool, but I’ve come to the opinion that this configuration is superior to the base configuration that comes with the printer. I do believe the fan runs quieter, is more structurally stable, and that it does a more precise job of ducting the air to the nozzle base.

Silicone Sock

Aftermarket 3d Printer Hot End Silicone Sock

I read about these after fixing a clog in my E3D V6 hot end a few weeks ago. The aftermarket hot end Silicone Sock runs about $8 and is well worth a try. The silicone sock keeps your hot end insulated, keeps it clean, and prevents against stray filament curling around, sticking to the hot end and the associated risk of creating a filament blob. There is a small risk the silicone sock could come lose and fall into your print during operations, but to date mine is fastened snugly on the hot end without issue since installation. In my opinion the silicone sock has done a great job to keep the hot end clean and in general improves the quality and reliability of the print.

Silicone Sock

Filament Extrusion Visualizer

The last upgrade I’ve made is a filament extrusion visualizer. This add-on is more aesthetically fun than anything else, but does have some minor functionality by quickly enabling you to observer how the extruded is operating at any given time.

The Prusa Extruder Visualizer tutorial has mostly windmill and screw type designs, but I chose to go with a nostalgic wind up toy configuration, but there are many fun Options to choose from. I’ve seen YouTube videos where the windup knob appears to crank in time lapse videos which also adds a pleasing visual effect. (Tinkering with 3d printing time lapse is on my to do list)

The set up is simple. You print your extruder visualizer, and then take a tiny Neodymium magnet

(8x3mm) and super glue it to the printer extrusion visualizer componen. The magnets make for interchange options.

3d printer extruder visualizer

COVID-19 Quarantine STEM: Elenco AmeriKit Learn to Solder Kit

Another weekend of COVID-19 quarantine lockdown means another weekend to dust off some of the STEM projects Santa Claus gave the kids this past Christmas that were sitting in the basement 😉

Elenco Amerikit Learn to Solder Kit

The kit impressed me. It comes with a decent soldering iron and a simplistic but effective stand for the soldering iron when not in use.

We divided work on the kit into two days . The first day they practiced soldering the pads on the circuit board and then soldering wire to the board.

My daughter is practicing her soldering skills

On the second day we assembled the kit. Along the way we got to discuss resistors, capacitors, transistors, and potentiometers.

Some of the electronics that came with the Elenco Amerikit learn to solder kit

After the kids had the basics of soldering down and were comfortable using the equipment we pivoted towards assembling the actual kit. I think it took us about 2 hours of relaxed zen-like soldering to complete the kit. It was very relaxing and enjoyable actually.

The kit is supposed to have flashing LEDs and a European siren when completed. We were able to get the LEDs to perform the alternating blinking pattern but alas, we could not get the siren to work on either child’s kit. We spent a good half hour troubleshooting, but in the end my hunch is that we may have applied too much heat to the 555 timer chips.

Final Thoughts:

We were somewhat disappointed we couldn’t get the siren to play after all of the components were soldered to the board, but I chalk that up to user error on our part. The real goal of having the children obtain a real world STEM skill of soldering was successfully accomplished. The kit was very effective at teaching this skill. Santa picked out a fun, practical, and educational gift for the kids to grow their soldering skills.

Hack the Pandemic – 3D printing COVID-19 Face Masks

I’ve been experimenting with printing face-masks to wear during the pandemic.

The .STL file was downloaded from Thingiverse .com and then printed on my Prusa I3 Mk3S 3D printer. I love the Prusa 3d printer. It is so choice. If you have the means, I highly recommend picking one up.

The parts for one COVID-19 mask take approximately 7 hours to 3D print.
This 3D print of 3D COVID-19 masks took 18 hours
Finished and assembled COVID-19 mask 3D printed on my Prusa I3 Mk3S

A HEPA filter from a HVAC unit or a vacuum cleaner bag can be cut to make the masks filter unit. I don’t have flexible filament on hand so the the mask is rigid. A rubber weather strip gasket can be used to line the interior for a gasket effect.

Cabin Fever Expo

Cabin Fever Expo
Model Engineering Show & Auction

One of my main reasons to acquire a Bridgeport milling machine and Grizzly lathe was to scratch this itch of mine to build model steam engines. It’s hard to explain, but I hear a calling to build these things. I got the idea to look for a model engine show for some inspiration and mentoring last February 2019, so I was very dismayed to learn that I had just missed one of the largest model engineering shows in my backyard by a few weeks: the Cabin Fever Expo held in Lebanon, PA. I marked Cabin Fever Expo 2020 on my calendar and waited with patience! After declaring my intent to attend this event, I was grateful to have my son state he was willing to tag along. After a somewhat grueling two hour drive on a blustery day into Pennsylvania in moderate sleet and snow we arrived!

The Cabin Fever Expo appears to be segregated into 4 areas, there are tool and part vendors, an ongoing auction with mostly model train parts for sale, a main hall with the model engines, a hall with consignment items for sale, and another hall with model boats, cars, tanks, etc.

We spent the majority of time in the main hall with the model engines. The craftsmanship is humbling. What used to be a practical trade has become a lost art of craftsmanship and manual precision engineering.


Obviously, we couldn’t leave empty handed! We purchased some lathe tool bit inserts, a coaxial indicator for the mill, a drill bit guide, and a beginner model engine castings kit.

Prusa i3 MK3S 3D Printer

My foray into 3d printing begins!

Santa got us a Prusa i3 MK3S 3D printer for Christmas . I’ve seen the Prusa crew and their printers in action several times at the NYC Maker Faire and at other smaller MakerFaire over the past three years. Make magazine has printed several articles in their “best gear” editions and the Prusa printers are almost unanimously identified as the best bang for the buck.

The unboxing of the Prusa i3 MK3S

The Prusa model comes in two options. There is a preassembled option for $999 and a build it yourself option for $750. I opted to go for the DIY built it yourself model. I’ve believed the only way to have a fully fundamental understanding of how the device works is to build it from the ground up. I also figured if the printer needed any future maintenance, repair, or installation of upgrades I would need this knowledge of how everything comes together.

Fasteners, fasteners, and more fasteners
It comes with all the tools you need to assemble
Partially assembled with a pause to eat the fabled Harbo gummy bears

The Build

I assumed the build would take a few hours (initially I just assumed less than 3). I was so naive! I read online that an average build time to put the 3d printer together can easily take 10 hours. I think mine took close to 16 hours. I really took my time with setting the tension of the belts and the final electrical wiring. If you are going to build your own printer from the Prusa kit I would recommend setting aside a large chunk of time (about 4 hours) over three days.

The kit comes with the infamous bag of gummy bears which seem novel at first, but rewarding yourself with the very specifically prescribed number when you finish the macro level sections of the build is surprisingly very rewarding and fun.

If you take your time, don’t rush, and read the instructions carefully, then almost anyone should be able to do this build. The final wiring up of all the servos, sensors, and power cables is relatively easy, it just requires a very slow and methodical attention to detail. I can’t tell you how relieved I was when the LCD powered on and fully successfully performed all of the calibration checks!

I did the majority of the build on the dining room table with my son and daughter watching closely beside tme. The build is an excellent way for young minds to see mechanical engineering principles slowly combine and manifest into a fully working device. As we built the printer we discussed concepts such as servo motors, the concept of a power supply, gears, set screws, linear bearings, hardened rods, extrusion nozzles, and sensors. I can’t understate the educational value of this build for young engineering minds.

First 3d print – A whistle!

Our first print was a whistle from the supplied SD card. It took about 20 minutes. After we got the hang of setting up the printer we printed a vase, a pug dog figure, and a gear set from files included with the SF card from Prusa. I am still amazed at the quality of the print. The detail exceeded my expectations. Simply unbelievable!

Ant weight “pusher” battle bot combat robot 3d printed by Prusa i3 MK3S

Since the main reason for getting the printer was to generate prototypes for combat robotics we pulled an ant-weight combat robotics .STL file from thingaverse to print. This print room about 6 hours. We let it run overnight, and like magic it was waiting for us there in the morning.

3d printed antweight combat robot body

Conclusions

Embrace technology! I’m excited for the moment when some small part breaks around the house and we can re-engineer a CAD file to print a replacement part on the spot. Just having the device here has me thinking about ways to use this new in-house (pun intended 😉 ) capability. The Prusa 3D printer models are the best value for your dollar and are an affordable foray into on-the-spot design and manufacturing. Building the unit from the parts level is a labor of love and an experience to be cherished.