OK, Jay, this clip takes a bit of set-up. Basically, it's a model of a factory-floor machine for moving pallets around a square assembly line. You put a pushing arm at each corner of the square and trigger them alternately in caddy-corner pairs. Some bright bulb figured out, however, that if you join two square tracks at one corner, you can do twice the work with only two more arms. Watch the intersection for a minute to confirm that the contents of the two square tracks are not mixed, which to me is counterintuitive. Here's a video of the simple, single-square case that apparently started the trend. [via The Automata / Automaton Blog]

I'm almost finished painting it, and I just string it all up for the first time since the project exposition to test out the new pickup magnets. It works GREAT! So amazing to play something I've built from the ground up. Just have to finish the fingerboard and bridge and then wait for the paint to finish curing so I can buff and polish it.

Most of the parts were designed in Open Office and cut on the lasercutter or Shopbot. To make his pickups, he created a magnet wire winder from lego parts and bench power supply.

Mark is a student at RIT and has been a youth leader in the Learn 2 Teach/Teach 2 Learn program operated out of the South End Technology Center with the help of the MIT Media Lab.

Tiny metal spheres are needed for tiny ball valves and tiny ball bearings, which are needed for all kinds of miniaturized machines. Hollow spheres are lighter, and thus have less inertia, and thus can be made to move faster in these very small applications, where response time is often critical. But how do you make a hollow metal sphere 2mm across? Turns out you can do it with one of the lost foam processes I'm always going on about. Tiny styrofoam beads are first coated with fine metal powder and a binder, then heat-treated to evaporate both binder and bead, leaving only a fragile hollow metal powder shell, which is then sintered into a continuous shell at higher temperature. Read more over at Science Daily.

We recently had a question from a reader about this prop. "Connie" wrote in wanting to know how to replicate the mechanism that, in the movie, is used to unlock The Book's cover. Never having seen The Mummy, I went into research mode and enqueued it from Netflix. Then I watched it. Big mistake.

But, you know, to each his or her own. And "The Book of the Dead," with its ornate clasps and intricate star-shaped key, is admittedly an awesome prop. The scene Connie is referring to, I believe, occurs at almost exactly one hour into the "Deluxe Edition" cut of the film, and shows the intrepid but remarkably foolish archeologists inserting the aforementioned star-shaped key into a correspondingly star-shaped opening in the book's cover, turning it, and thereby releasing the spring-loaded cover clasps and, with them, all manner of unpleasant whatnot.

So I started Googling around, looking for dweebs enthusiasts that might have already built such a thing. And while I did not find any working mechanical replicas of the prop, I did discover the remarkably beautiful static replica shown in the photo at the top of this post by Jeff Stelter of Stelter Creative Woodworks.

I also found this video by YouTuber oneandonlyJadedMonk showing his working mechanical replica of the star-shaped key used to open the book. Connie, if you're looking for a real expert, I think this might be the man to talk to.

But as for completely working cover locks, I'm afraid I have to admit defeat. Having watched the scene a few times, I'm completely confident that a suitable lockwork could be designed and built, but actually doing either is well above my pay grade. But something I've learned writing for this blog is what an incredible resource the MAKE readership can be, and so I'm going to throw the question out to them.

How 'bout it, folks? Anybody know how this thing works? Or know of somebody's who has built one? Or, even better, know anything about the original prop?

Make: Halloween Contest 2009

Microchip Technology Inc. and MAKE have teamed up to present to you the Make: Halloween Contest 2009! Show us your embedded microcontroller Halloween projects and you could be chosen as a winner.

Cool post over on Hack-A-Day about corn maze entrepreneur Scott Skelly, shown above with his trusty GPS-enabled riding lawn mower. Scott explains his maize-maze-making process thusly:

A maze starts as nothing more than a large field of corn. The design is created using a computer, then translated into GPS coordinates by fitting it into a field whose outline coordinates were previously captured on foot. Once the field coordinates are reconciled with the map design the data is used in one of two ways; the routes can be made by tilling under a path when the corn is very young, or more commonly it is cut lawn-mower-style when the corn is anywhere from knee-high to full grown. This corn-meets-satellite hack makes for a whole lot of fun!

Never happen! But it's neat looking, and it uses some impressive sounding industrial process called "impact extrusion," and its proving to be a pretty effective advertisements for its designer Dzmitry Samal. [via Gizmodo]

Peter Maltzan is building a passive solar straw-bale house, and has been at it since October of 2008. He's done a great job of documenting the construction process, which is now nearly complete, in photographs. Highly recommended if you want to get a feel for how it all goes together. Thanks to MAKE subscriber Pete Marchetto for suggesting the link.

If you have a game, but no ball, and the closest sporting goods store is miles away, what are you going to do? Make one, of course! Check out this video to learn how to make a soccer ball using plastic bags and other readily available items.

[via afrigadget]

Check out these animations of cranes being erected, one even erects itself! And for a little crane game fun, check out Crane Wars.

Back in March, Becky posted a link to a lampshade I made using this technique. Instructables user quixotiCfluX has posted a great tutorial showing the details of the process. He uses a cool trick with a staple remover to make sure all the tabs have exactly the same bend, which results in very uniform maille.

Sam Brown points out this video visit to the workshop of high-end knifemaker Joel Bukiewicz. It's a nice little documentary that avoids rushing through the topic, covering a bunch of excellent details from an otherwise private, happily-obsessive process. Plus Joel gives his take on some aspects of the craft few know about. Some more info over @ CHOW.

Related:

How knives are made

We've seen plenty of creative USB flash drive rehousings in the past, but the above vid from NetbookNews gives a peek into the original manufacturing process for the popular device. Hmm - would be kind of neat if the drives were also available caseless. [Thanks, Sascha!]

Tired of informative videos that explain exactly how different kinds of consumer devices are made? Then you will love this "instructional" video by YouTube user HowThingsAreMade!

[via Creative Synthesis]

Wondering what to do with that snake farm under your desk? Check out this rain gutter solution. Nice and neat. Via Kat on Twitter.

Terry Trier has written a good tutorial on carving this classic whimsy from a single piece of wood.

Concrete-jungle.org shares pics of this human-powered apple munching machine, constructed for their annual Ciderfest -

Aluminum tube mounted on elevated plywood frame, with space underneath for a 5 gallon bucket to catch apple pomace.

1" shaft through the tube, with a 25lb flywheel and 18t bicycle freewheel mounted on flange bearings.

Mike Firth is a hobby glassblower in Dallas, Texas. His site includes a great page on a variety of techniques that can be applied to reclaimed glass bottles, including several methods of cutting them. The site also describes more exotic bottle-working techniques like slumping, stretching, drilling, and blowing out.

Thanks to Gareth and all my Maker Media associates for giving me this opportunity to author some articles online. My new book, Absinthe & Flamethrowers, contains a number of projects that I think most makers will find interesting. It's probably worth noting that there are sections on making and doing stuff that, well, may seem a little dangerous to some.

Note the adjective "little." There's a difference between interestingly dangerous and crazy dangerous. I believe the content of my book falls within bounds of the former. Part of the reason I wrote it was to explore the spirit of courageous discovery that filled the lives of people like Thomas Edison, Amelia Earhart, Francis Crick, and Gordon Moore.

Read their biographies and you'll find out that these people worked on the edge, and prospered by doing so. Sometimes making things involves a bit of risk and I think many of the best makers embrace that and know the boundaries between cool and crazy. So, I've included projects there such as making your own gunpowder, chemical rockets, and yes, even a flamethrower.

One of the sections is on the art and science of enjoying absinthe, the wormwood-based alcoholic beverage that was deemed too dangerous for regular people to consume and made illegal in most of the world for nearly a century. But now, it's back, and becoming very popular once again.

One way of enjoying absinthe is to drip water onto a sugar cube carefully positioned on a slotted spoon over a glass of absinthe. Hardcore absinthe devotees typically use a fountain that looks like this.



Being a frugal maker, I built the water dripper in the photo (it's called a "fountain" by absinthe connoisseurs.) It issues two precisely controlled drips of very cold water. The drops fall on a sugar cube which slowly dissolves into the absinthe. This is the approved method of tempering one's absinthe (most people won't want to drink the stuff straight - it's usually 120 proof or more.) As the sugar water falls into the absinthe, it undergoes the famous color change called the "louche," prized by absinthe imbibers, turning from clear green to a milky opalescence.


I made the fountain in a couple of hours from clear PVC, type L copper tube, and two small gate valves. I found the gate valves at the local hardware store for a couple of dollars each. The copper tube is sealed with epoxy into the PVC water chamber and the gate valves attach via compression fittings.

A votre sante!

Ask MAKE is a weekly column where we answer reader questions, like yours. Write them in to becky@makezine.com or drop us a line on Twitter. We can't wait to tackle your conundrums!

Dan writes in:

How are big closed cell polystyrene bocks made? I've seen them 12" square and about 8' long.

Expanded polystyrene foam (EPS or Styrofoam) is made from pellets of polystyrene, which is a plastic made from crude oil. The pellets are expanded in a steam chamber. You can find these pellets in this form inside most beanbag chairs. To make solid objects, they use steam molds that fill a chamber with the pellets, then steam fuse them into custom packaging, foam drinking cups, etc. Here are a few videos I found on the topic; one's on Planet Green, the other one is a segment on Discovery's How It's Made:

More:

• Styrobot built by father & son (pictured above)
  
• Styrofoam chandelier
  
• Moldable plastic from styrofoam
  
• Hot wire foam cutter

By Eric Chu, engineering intern

Hammers have been used for millions of years, evolving from a primitive stone tool to the combinations of metals, woods, and plastics commonly seen today. Here's my version in solid steel.

I made this steel hammer in my beginner's manual machining class, for the class final. This is no ordinary hammer. It's roughly twice the weight and size of a normal hammer, so it has lots of power behind it when swung! I made it using a manual lathe and utilizing most of the lathe's tools. Check out my results:

The hammer is actually made of 2 parts: the head and the handle.

As part of his attempt at manufacturing a toaster from scratch(!), Thomas Thwaites had to figure a way to smelt his own iron (for the grill piece) -

Finding ways to process the raw materials on a domestic scale is also an issue. For example, my first attempt to extract metal involved a chimney pot, some hair-dryers, a leaf blower, and a methodology from the 15th century – this is about the level of technology we can manage when we're acting alone. I failed to get pure enough iron in this way, though if I'd tried a few more times and refined my technique and knowledge of the process I probably would've managed in the end. Instead I found a 2001 patent about industrial smelting of Iron ores using microwave energy.

Microwaves, as we all know, are just so much more convenient - and so I tried to replicate the industrial process outlined in the patent using a domestic microwave. After some not-so-careful experimentation which necessitated another microwave, followed by some careful experimentation, I got the timing and ingredients right and made a blob of iron about as big as a 10p coin.

A few weeks ago my daughter made a mermaid tail at her friend's birthday party. It was a fun project, and swimming at the pool is a whole different experience now.

In her notes on the video, Sasha says that she got the swim/dance wear material at her local fabric store.

Dark night, bright flashes, ooooh, ahhhh....hmmmm, how does that work? Here is a collection of how those flashy bangs and pops do their thing.

How Stuff Works does a typically thorough job explaining the hows and whys of fireworks.

When the fuse burns into the shell, it ignites the bursting charge, causing the shell to explode. The explosion ignites the outside of the stars, which begin to burn with bright showers of sparks. Since the explosion throws the stars in all directions, you get the huge sphere of sparkling light that is so familiar at fireworks displays.

Pyrouniverse is up for giving the abstract on how they are loaded, but keep their lips sealed on the ancient family secrets.

Fireworks tubes are made by rolling thick paper tightly around a former, such as a dowel. Though they can be made by hand, most firework/tube factories use machinery to manufacture tubes.

The shells that hold the individual charges are loaded with various metals and other ingredients.

Inside a shell are pellets that, when burning, produce the colors in a fireworks explosion. Various compounds create various colors -- strontium gets you red; barium, green; copper, blue; sodium, yellow. Aluminum, titanium and magnesium brighten the flames.

The Boston fireworks show has a tradition of drawing huge, potentially panic attack producing crowds. Each of the charges have been built and are planned and manufactured for months in advance. When the time comes, they will be fired off in coordination with the music emanating from the stage.

They downloaded the soundtrack onto a specially designed computer system and began the time-consuming work of matching their arsenal of Roman Candles, Comets, Meteors, Spinning Wheels, and other fireworks with the rhythm of the music.

"You judge what to use by the feel of the music,'' Art Rozzi said. "You have to know what you've got. You have to know if you're going to shoot a lot or a little. And you have to keep in mind the finale, so you're not giving anything away.''

Though many cities have fireworks shows, lots are also dampening the fuse this year because of the expense and budget priorities. For the lucky remainders, people have been prepping the sites for the past few days and weeks.

Each firework is encased in a shell that looks like an oversized light bulb wrapped in brown paper. Inside, one fuse launches the firework like a rocket, while another has a time delay that makes it burst in the air.

The fireworks are made of gunpowder and beads that form various shapes and colors depending on the chemical pigments and how they are arranged inside. They come from all over the world, though most are from China.

The color of a compound in a firework will be the same as its color in a flame test. Not all compounds that produce a colored flame are appropriate for coloring fireworks, however. Ideal colorants will produce a pure, intense color when present in moderate concentration.

Share with us in the comments your experiences of making and deploying fireworks.

Image above from Wikipedia

There are a few clever pranks here. I particularly like the Mentos stealth geyser. From the Mischief Makers' Manual.

AIDG is a NonGovernmental Organization (NGO) that helps provide low technology solutions to help address environmental and health needs to people living in communities without great access to the systems that many of us consider requirements.

Here are a few of their water-based initiatives:

Solar Hot Water:

XelaTeco, with support from AIDG's wonderful interns, recently installed a solar water heating system and water tower for La Guarderia, a childcare center in Llanos del Pinal, Guatemala. La Guarderia was started by two non-profit organizations, Pop Wuj and Jóvenes Juntos, who saw the need for daycare and after school homework assistance in a community plagued by poverty, domestic violence and alcoholism.

Jóvenes Juntos requested the hot water system to promote healthy hygiene practices amongst the children served by center, particularly in the cold winter months. The presence of hot water is expected to reduce the occurrence of skin ailments, such as scabies and other rashes. This segment of the project was funded by AIDG.

Ram Pump:

As the water runs downhill from the source to the ram pump, it gains force and velocity. When this velocity reaches a determined point, the water closes a valve in the ram pump known as the "impulse" or "waste" valve. The force of the water against the now closed impulse valve causes pressure to build inside the pump. The water sends high-pressure shock waves in all directions (the "water hammer," or "ariete" in Spanish, from which the pump gets its Spanish name, "Bomba de Ariete"). These shock waves open another valve, the delivery check valve, and water squirts through reaching altitudes of up to ten times greater than the vertical distance from the water's source to the pump. An air vessel installed in the pump acts as a kind of regulator which keeps the flow at the top steady, instead of delivered in bursts, as the pump internally functions

Sand Filtration:

Properly managed sand filters remove 96%-98% of water borne pathogens such as E. Coli and Giardia, producing a positive significant impact on the health of target users. The greatest effect is expected for young children, who are extremely susceptible to diarrheal diseases caused by exposure to contaminated water. Diarrheal disease causes approximately 2 million deaths per year among children in developing countries.

The World Health Organization has some good documentation on sand filtration technology.

To find out more about AIDG, check out their blog and their photos.

Michael Jackson's death caused radio's roboprogrammers to take a back seat for a while. Increasingly, over the past few decades, broadcast radio has ceased to be a local affair. As the FCC regulations on local ownership of media outlets has faded towards corporate behemoths, radio programming more and more these days is done by databases and distant decision makers. For those of us who remember real radio dj's who made personal decisions about what song would come next, this has driven us more towards our own music collection, rather than being stuck listening to the corporate drivel. Pandora and Last.fm are okay, but they lack the personal touch.

With Michael Jackson's death announcement, the clacker driven music machine was taken off line, if only for a few hours and only on a few stations. Human beings again ruled the airwaves of some radio stations.

"It's a good reminder of what live radio can do, of the role that radio can play in bringing a community together,'' said Scott Fybush, editor of Northeast Radio Watch in Rochester, N.Y.

Many stations no longer have live announcers, using canned voices for part or all of the day, and so can't react to a major news event, he said.

DJ Deirdre Dagata, 39, has been working at Mix 98.5 part time since May, after being replaced at Kiss 108 by recorded programming the month before. And yesterday, she was back in action for the biggest radio day in memory.

Dagata was in constant motion during her 9 a.m. to 2 p.m. shift. Sitting in an elevated office chair in front of four computer screens, she punched blinking phone lines, tapped on keys, and slid knobs - simultaneously editing recorded calls and fielding a steady stream of new ones from listeners who wanted to share stories about Jackson.

Back in the day, I recall listening to the radio knowing something unique was happening. The radio announcers had their own tastes in music, and they helped to create a following around their musical tastes. Sometimes there was dead air as the dj missed the cue for a variety of human reasons, some more innocent than others. This caused me to volunteer at and work at several radio stations in the 1980's and 1990's. I actually chose my university because I liked the on air feel of the campus radio station, which turned out to be a very influential organization for me. At the station, I did on-air work, production of public service announcements, newscasts, dj training, and eventually became Program Director. The audience's active listenership of the music and programming was exciting to be involved with.

Back then, radio was a public service to be provided to the community, not just a marketing opportunity. Almost radio programming was done with people at the microphones, nearly always they were playing actual records, tapes or cds. Even the commercials were created in-house, except those for national campaigns.

Do you miss real radio? There are a bunch of college radio stations around, and most of them depend on the student body and sometimes local community members to create their programming. With web streaming, it is possible to listen way beyond the broadcast range of your favorite station. WERS in Boston plays a good mix curated by communications students. KEXP in Seattle has a wonderful mix of live performances and genuine djs choosing the music they play. Transom and Youth Radio are helping to cultivate the new voices of radio that we need. Public Radio Exchange has a channel on XM radio, and features a mix of voices that you may not have heard before.

With podcasting and the great suite of computer software and hardware available for free, just about everybody has the radio recording studio in their laptop, desktop, cellphone and digital camera that I had in my bedroom as a high school kid. If you want to broadcast, you may want to build your own transmitter. Sending out your homebrew radio programming out to your house or close neighbors could be a neat experience. You could record some short pieces like songs, jokes, or seque buffers, drop them into your music library and set your music player loose, sending your personalized radio program out to the transmitter.

Radio used to be a LOT of fun as a listener and programmer. Now the tools are much easier to get and use for us regular folks. Hopefully, the corporations will lighten up on their centralized programming and return to the human touch of radio, but even if they don't we can realize that we can choose what radio we listen to or create. If you have any stories of making your own or listening to real radio, pirate or otherwise, tell us in the comments.

Rick began with a styrofoam mold he had created already.

He had built his own burner for melting scrap aluminum. (He said that you can't do this using aluminum cans.)

He buried the mold in a bucket of sand. When the aluminum was red-hot, the exciting time for the pour arrived. In the video below, listen to the enthusiastic audience and their questions -- this is why these demos are so cool.

Minutes later, after the mold had cooled, he removed it, dunked it water, and raised it high to the delight of the crowd -- a metal Make sign!

Rick recommends the site, Backyard Metalcasting, for instructions on how to do this yourself. He also credits the Dave Gingery books available from Lindsay's Technical Books.

Thanks to Dale Grover and A2 Mechshop for inviting me to speak and to the hundred or so who came out.
A2 Mech Shop, a "co-engineering" space, is a positive sign that good things are happening in Michigan.

This reconstruction of the earliest known olive oil factory demonstrates a simple yet ingenious process to extract olive oil from olives using pulleys, levers, and gravity decanting. This was much more effective than using mortar and pestle to make olive oil, typically used for small scale production. Dating back to the 6th century BC, this factory was located in the Ionian city of Clazomenae, on what is now the coast of western Turkey. This photo shows the press used to squeeze the olive oil out from burlap sacks filled with a paste of ground up olives.

Here's a traditional wood-bending technique that seems ready-made for CNC millers, and yet I can't find much online evidence that it's being done.

To make a kerf-bend, the wood is first corrugated on the inside of the intended radius. The width, depth, number, and spacing of the kerfs all affect the qualities of the finished bend. The open kerfs are flooded with glue, and the bend is made and clamped in place until the glue dries. Stuart Lees of Stu's Shed has a nice piece on the subject.

I imagine it's tedious work, cutting all those kerfs, at least if you're doing it manually with traditional tools, like a table saw or a fence router. And perhaps more intimidating, for some, is the mathematics of figuring out just how many kerfs you need, and just how thick, deep, and widely spaced they ought to be to achieve a particular radius. Yet both functions can be performed automatically by a CNC system--the cutting by the hardware and the calculating by the software.

In fact, it seems like such a natural fit that I'm having a hard time believing it's not already out there. So sound off, CNC-millers: Who's doing this today, and where can I learn more about it?

Anybody else read Snow Crash? Remember the big scary Aleut who likes to steal warheads from nuclear submarines using only his canoe and handmade glass knife? Remember how, when you first read that book, you kinda wanted to be that guy? Well, I'm here telling you: It's not too late to become the baddest mango-farmer in the world. After all, even Raven had to start somewhere, and apparently chipping an arrowhead out of bottle glass is the "hello world" of the flintknapping user community. Mike Melbourne and Tim Rast's venerable tutorial shows you how.