DIY Projects | Home, DIY & Stuff

DIY Projects

DIY Projects for the home or workshop.

DIY Oven Build Using a Filing Cabinet

April 26, 2016
By
Cheap and extremely effective! A DIY Oven for DIY powder coating, wood drying, acrylics and plastic; you name it!

Cheap and extremely effective! A DIY Oven for DIY powder coating, wood drying, acrylics and plastic and any other idea that needs heating or baking in future.

You did what?  Hacked a filing cabinet to make a home DIY workshop oven?!

Yes, perhaps we are crazy, but this DIY oven really IS made from a standard office filing cabinet and it works like a dream!

It is great for curing electrostatic powder coating on CNC milled metal parts; melting plastics; bending acrylics; scorching wood, sealing natural bamboo wood wax and any number of other DIY projects where oven heating is required.

See more about how we made this DIY oven from a filing cabinet here.

Industrial, or even DIY hobby ovens are extremely useful in a home DIY workshop. Unfortunately, they are also usually unjustifiably costly for most small projects.

Cheap toaster ovens can be used for small scale applications as a ‘make-do’ alternative, but are often not physically large enough to fit many DIY projects.  They also usually offer very poor thermal efficiency.  A big downside when working over longer periods as the units tend to get hot inside as well as out.

We recently cut some large aluminium parts and components using our home built CNC machine. We wanted to coat the metal parts using an electrostatic powder coating system to give them a lasting professional finish. Powder coat curing however, requires parts to be heated to high temperatures for extended periods. (And strangely, the cooking department said the kitchen oven was considered off limits well before we mentioned curing powder coat paint or the carcinogenic gases they produce….)

We needed a large, cheap DIY solution. A robust, purpose built DIY oven capable of maintaining high, evenly dispersed temperatures for lengthy periods.

Read more »

Making a Home DIY Metal Sheet Bender

January 26, 2016
By
Precision Folds from a DIY Sheet Metal and Acrylic Bender

Precision 90 degree bends in 2mm thick metal plate, made by a DIY sheet metal, plastics and acrylic bending machine.

We suddenly had the desperate need to bend stuff in the workshop!

We are talking 2mm steel sheet.  And we were not wanting to just destroy it with low quality folds either, but to effectively and precisely bend it at pre-determined fold lines to produce professional looking folds repetitively, piece after piece.

In material like 2mm sheet metal, precise 90 degree bends with quality edges would normally be a relatively difficult and frustrating task for home DIYer’s without the right equipment – as just happened to be the case for us.

So we decided to work smarter and put the DIY gray matter into gear.

After some quick mental design work and an hour or two in the workshop, we had made our new Home DIY Sheet Metal Bending Machine – See the project page here.

The tool worked extremely well and did fantastic metal folds. We later realized it was also great for bending acrylic and other plastics too!

As it turns out, we had produced an extremely simple, but very effective design.

Our DIY sheet metal bender provides sharp and professional looking bends in 0.5mm to 2mm thick steel, tin and aluminum sheet. It also does a great job of folding acrylic and plastic of up to 10mm thick (with external heat).  Maybe even thicker!

Read more »

Making DIY Miso Paste with Soy Beans (Half Year Update)

June 28, 2015
By
DIY Miso Paste made from Soy Beans is mixed at six month milestone.

At the six month milestone, DIY Miso paste requires mixing of the blended Soy Bean ingredients to help development of flavor.

Spring SeasonMiso paste is an ancient Japanese preparation with origins dating back almost a thousand years. The pungent fermented food has an acquired taste, but is extremely healthy as an addition to many popular Japanese dishes.

We wrote about making Miso earlier in the year in our blog post here.

We also produced a step-by-step guide to making DIY Miso paste for those interested in having a shot at making it at home themselves.

With our DIY paste having quietly sat in a cool place for almost half a year, it is about to enter a new Summer phase of fermentation. It was therefore time to re-visit our DIY Miso paste to give it a good thorough mixing to help aerate and redistribute the fermentation culture to ensure development of a rich and consistent taste.

Our home Miso paste project was started in late Winter, which we timed so that ingredients and base flavors had a chance to soak together and spread evenly throughout the entire mixture before Summer heat arrived. The next Summer phase however, is when the real added flavor and character of the Miso develops. As the temperature rises, the fermentation culture kicks into overdrive.

Read more »

Fixing a Dremel® Hand Held Rotary Drill – A Step-by-Step Guide

May 26, 2015
By

 

Dremel® Multipro (Model 395) Rotary Drill.

There comes a sad time when all great and trusty tools in the workshop begin to die from overuse.

Murphy’s Law states that this must occur at the most inopportune time. In the case of our ever faithful hand held Dremel® MultiPro rotary drill, this breakdown just happened to be in the middle of an important PCB shaping, drilling and cutting project.  Our rotary drilling tool was mounted as a router on top of a mini CNC machine at the time.

Dremel® Hand Rotary Drilling Tool - Exploded Parts Anterior View

Dremel® Hand Rotary Drilling Tool – Exploded Parts
(Click to see our step-by-step hand held rotary drill strip down guide.)

When the problem started, the tool motor suddenly became erratic and there were problems with the variable speed control (VSC) switch. Then, the sliding switch no longer provided any motor speed control what-so-ever.  It only provided power ON at full speed – a heat blasting 35,000rpm …. and a silent OFF.  This wasn’t at all ideal for our CNC cutting project where cutter heat control was important.

So what was our obvious DIY reaction to this? Find the cause and fix the tool ourselves of course!

You can find photos showing how the internals of our Dremel® MultiPro tool looked here.  We have also provided a step-by-step dialogue on how the tool was taken apart; how the faulty part was found and replaced AND importantly, how the hand held drill was successfully put back together again!
Read more »

Replacing Japanese Tatami Mat Flooring

February 6, 2015
By
Japanese Tatami Room

A traditional Japanese tatami room with floor panels made of Igusa (rush) straw fibre.

Tatami rooms are a wonderful part of many Japanese homes. They are elegant and stylish.

But look up “Japanese tatami room” in any Japanese DIY handyman’s manual and within the first few paragraphs, any guide will likely mention the notorious requirement for constant care, cleaning and replacement of materials in order to maintain their appearance.

Most materials used in the construction and decoration of traditional tatami rooms are natural fiber products, including raw pine wood, rush fiber and rice paper. The rooms look and smell great when they are fresh and new, but deteriorate, yellow and mould with age.

Earlier, we provided tips for renewing aged and discolored rice paper on the Japanese Shoji paper doors of tatami rooms. Now we turn our focus to replacing tatami floor panels – a larger, more expensive and somewhat more involved renewal job.

Watch the making of Japanese tatami mats on Youtube here.

Traditional tatami floor panels are usually made from neatly woven mats of rush fibre (ie: Igusa plant) stretched over and sewn onto thick blocks of compacted straw from the same plant.

In recent years, lighter weight, synthetically backed tatami flooring panel alternatives have also become available. Some are often considered significantly inferior by traditionalists, but they do have benefits.

Read more »

Making DIY CNC Clamps and Knobs – Free G-Code Download

January 26, 2015
By
CNC DIY holddown clamp

Moving material blocks cause lots of failed CNC project attempts. Having ample CNC machine clamps on hand always helps prevent material movement problems.

There is nothing more frustrating than completing a lengthy DIY CNC design cut, only to find the wood or aluminium material block has moved during the program – rendering the material and entire project cut-out attempt  useless.

We “clamped down” on this problem long ago in our DIY workshop, but we always like to remind new CNC machine builders that you can never have too many clamps on hand.

The problems extending from small amounts of material slippage on a CNC table are often the hardest to identify.  The problems are often blamed on other machine components, such as faulty CNC motor driver controllers, slipping shaft joints, structural flex, or backlash.

We’ve found that many of these DIY workshop problems are solved by having ample clamps and clamping positions available for use on the machining table.  This ensures your projects stay securely in place and that they are cut correctly every time.

Hold down clamps in themselves are cheap and easy to make.  Three to six clamps made of 5-7 mm thick steel with a slight bend at one end (coated in a tough powder coat paint), is usually enough to hold wood or aluminium material blocks firmly in place for most projects.  Being made of steel, the clamps have some inherent ‘springiness’ in them making them easy to place on and off a part (unlike block aluminium clamp alternatives).

DIY CNC Hold Down Clamp Knob

Easy turn DIY CNC clamp knobs are quick, cheap and simple to make for yourself, with your own CNC machine!

Making the ‘easy turn’ DIY knobs for your CNC machine clamps is also super easy …. using your CNC machine!

With our free g-code, dxf and crv files available for download, you don’t even need to design the knobs yourself. You can download the files and import them into your CNC machine design software right now!

The downloadable knob design provided is sized for M8 bolt heads (ie: bolt shaft diameter 8mm, head hex width 13mm) embedded in 13mm thick high density plastic material, but the basic CNC machine g-code or crv design file (for Ventric and other compatible design software)  can easily be resized, recoded, or redrawn to suit other bolt sizes and material thickness’s. Read more »

Making Miso from Soy Beans – We’re all go!

January 18, 2015
By
Japanese miso paste

Japanese miso paste

winter-seasonA couple of weeks back we announced that we had received a DIY Miso making pack in preparation for our trek back into Japanese tradition and the ancient techniques of preparing this unique Japanese food. (The earlier story is here).

The DIY Miso kit was purchased from a special Miso manufacturing company called “Komego“, located in Fukui, Japan.  (At this stage, the company only supplies the kits to customers within Japan and website and all kit instructions are only written in Japanese.)

A complete step-by-step guide to how we made our Miso paste is provided here. We will update this guide as we continue fermentation and eventually re-mix and finally eat the Miso later in the year.

Japanese are usually very particular about the differing types and tastes of foods as produced by specialist regions of Japan.  Miso products are no different.  Various types of Miso can be produced with the taste depending on the origin of specific ingredients and the specific regional preparation techniques employed to make the paste. Read more »

Etching DIY Circuit Boards (PCB)

November 29, 2014
By

PCB Screen PrintingElectronics hobbyists who have never ventured into the realms of making their own circuit boards, are missing out on half the fun.  Here, we present a quick step-by-step guide to the UV light transfer and Ferric Chloride etching method for making your own printed circuit boards.

Home DIY electronics projects can be a lot of fun for discovery and learning.  They can also be extremely useful for those  extra buttons and remote devices in your home.

What is even better, is being able sit the project components on a printed circuit board (PCB) that you also made yourself.

It is extremely satisfying seeing a finished DIY electronics project which looks so professional it could have just as easily come from the nearest electronics store.  Learning the skill of etching your own PCBs will help you obtain that same satisfaction in your home electronics projects too.

Read more »

Japanese Miso – DIY Fermentation Project Complete

November 20, 2014
By

winter-season

DIY Japanese Miso Cracker Dip

We have completed the fermentation of our DIY Japanese Miso Paste from raw soy beans.  The Miso making was a great success.

Many readers could be forgiven for reacting with an “Eeuuuwwwww!” upon seeing some of the photos of this process, but believe us, the final miso paste product is extremely tasty.  And healthy too!

It has been almost a full year since we started making our paste. The fermentation started in cold Winter months early in the year, soon after when we first discussed home DIY miso making. We later provided a full DIY how-to of miso making guide” when we started the mix, where we showed the ingredients required in the preparation and the techniques used.

Time has flown by. We provided a half year report on the progress of our fermentation project when the soy bean paste received a good mixing just prior to the arrival of Summer’s full heat. At the time, being exposed to only cool temperatures, little had changed in our premature miso paste and there wasn’t even a thread of flavor altering mold to be seen.

Given five extra months of development and an a blast of Japanese Summer heat in between, and that all changed!

Read more »

Home DIY Electrostatic Powder Coating

November 2, 2014
By
Electrostatic Powder Coating Spray Unit

DIY electrostatic powder coating requires some upfront investment in workshop equipment, but the surface coating results are worth every cent!

brush-100x100We can’t rave enough about electrostatic powder coating in our DIY workshop.

Why? Because even when most liquid paints let us down completely, electrostatic powder coat paints consistently give our metal DIY parts and projects an extremely professional looking finish.

There are no spray cans, liquid solvents or messy paint brushes involved in powder coating.

The paint is supplied as a dry, finely milled powder and applied using a specially designed electrostatic spray gun.

The array of powder coat colors available, with finishes, metallic effects and textures to suit any DIY project desire or need, is stunning. Powder coated finishes are quality coatings which are thick, vibrant and extremely scratch resistant.  They last!

With powder coating equipment available, a fully protective dimpled coating in an exotically wild metallic red or green color over a metal surface is simple to achieve – whether with or without an holographic like lustre! As is a a more conservative, yet very professional looking coating of silky matte black.

The ability to spray this level of coating quality at home expands all sorts of DIY project horizons.

Unlike liquid paints, powder paint can be applied evenly in one shoot without the risk of dripping or sagging. Over spray can be easily swept up and re-used.

Following a paint shoot, the coating is cured by heat treatment. Then, after just 20 minutes in a workshop oven …. the job is done!  The parts are good to go!
Read more »