Necessity is the Mother ofInventionInvention

The Sequel A Primer for Aspiring Do-It-Yourselfers

Dave Yates and Gary Bennett

SOME THINGS CAN’T BE BOUGHT, SO MAKE IT

YOURSELFYOURSELF

Objectives

•Bring out the “MacGyver” instinct in you

Demonstrate ho common ood orking tools can be sed to•Demonstrate how common woodworking tools can be used to fabricate with aluminum

•Simple electrical projects that you can make yourself

•Plans, schematics, complete “how-to” are available for downloadavailable for download

About us:

Gary•Profession - Database marketing services •Home handyman

t•1st telescope 6 years ago : •EXT125PE•LX200 10” “Classic – f/6.3! Had millennium bug•CPC 1100 11” SCT “pimped to the extreme”

•Astrophotography obsession began 3 years ago

•Wedge mounted CPC11, piggy-back refractor…THEN:

•Celestron CGE EQ mount – highly modified•Televue NP-101is•AstroTech AT10RC•AT66 APO – Guide Scope, SSAG Autoguider•SBIG ST-8300 CCDSBIG ST 8300 CCD•Moonlite Focusers with high-res stepper motors

Published Articles:-CPC1100 – how to replace nylon bearingsCPC1100 how to replace nylon bearings

-Celestron CGE mount – Motor control cable replacement

DaveDave•My “Obiwan” of all things electrical and mechanical•Current profession: Precision Instrument Technician – Medical Diagnostic EquipmentDiagnostic Equipment•AutoCAD designer•Extensive background in metal fabrication (milling, lathe, etc.)•We all need to make friends with someone like Dave.

Astronomy Experience – 3 months behind me for every step of the way y•Regular contributor to numerous “Yahoo” Newsgroups:

•NexStar•Celestron - CPCCelestron CPC•EQ6 / EQMOD•CGE•etcetc

•1st scope 5 ½ years ago1 scope 5 ½ years ago•114GT GoTo•Meade LXD75, 8” Schmidt Newt (bad news!)CPC800 3 th l t•CPC800…3 months later,

aperture fever .. CPC1100•Current:

•CGE Mount•Every kind of scope ever made

Are you like me?Are you like me?Typical Experiences

• After buying your first telescope you probably learned that the “big ticket item” was the cheap part compared to the cost of all the p p paccessories that you needed.

• Many of us did the “I’ve got a telescope and camera; I think I’ll doMany of us did the I ve got a telescope and camera; I think I ll do some astrophotography”. If this is you, then this presentation is especially for you.

• Wiggly / Giggly mounts take all the fun out of it

Electronic idgets Miles of ires and adapters of e er kind• Electronic widgets = Miles of wires and adapters of every kind

•As you progressed in the hobby, you probably discovered that “MacGyvering” became a necessary skill.

•You want to try astrophotography and discover you’ll need:•43 pounds of AC adapters and cablesp p•A power supply that is capable of powering a small city

• Many of us have spent a lot of time and money trying to findMany of us have spent a lot of time and money trying to find solutions only to discover that what you need is:

Not commercially availableCost is well beyond your credit card limit, or financial committee y yapproval.

G ’ T R t kGary’s Top Reasons to make you own:•No one makes it•I need it•I need it•Commercial version is:

•Poor qualityPoor quality•Wrong size•Takes too long for delivery

• Save money? – NOT•I love tinkering and it looks like fun

Dave’s Rule:L t G b th “t il bl ” d b it•Let Gary be the “trail blazer” and buy it

first•Then I will find a way to make a better oneone. •OR…..I will buy his old toy at half price.

ELECTRICAL PROJECTS AND OTHER “PLUMBING” IMPROVEMENTS

JUST SAY NOAstronomy equipment is plagued by poor choices for plugs:

•Power plugs•“Phone Plugs” •And many more

Fortunately, there is an easy cure

PLUGS O’PLENTY

PLUMBING IMPROVEMENTS – PART 1

Ditch the “Bayonet” Power Plug

EQ6 POWER PLUG MODIFICATION

Make your own Telrad Dew Heater

• This is a really simple, fun project that can be done in 1 hour or less

y

• This really “hot” project is by far the most effective, tidiest heater available

• It works unbelievably welly• Can’t be bought – you need to

make it yourself• Cost is less than $ 10.00

TELRAD HEATER – WIRINGTELRAD HEATER WIRING DIAGRAM

Parts needed:Parts needed:•2 watt, 100-120 Ohm resistor•RCA Female chassis mount•RCA Male plugs (1 at each end) with wire toRCA Male plugs (1 at each end) with wire to connect heater to dew controller•2 pieces of wire•Heat shrink tubingg•Solder – 60/40 rosin core•Black duct tape•Dab of clear silicone caulking

Tools Needed•Soldering Iron•Wire stripper•Wire stripper•Needle nose pliers•Phillips screwdriver•Hot melt glue gun (optional)Hot melt glue gun (optional)

PLUMBING IMPROVEMENTS – PART 2

Does this look familiar?•AC adapter for 12V DC Scope PowerPower•AC adapter for CCD 12V DC CameraAC d t f 12V DC F•AC adapter for 12V DC Focuser

Motor•AC adapter for 5V DC USB Hub•AC adapter for 8VDC DSLR Camera•12V DC Battery for 12V Dew Heater Controller

WHY NOT…..

•Run everything from DC power to begin with?B ild “Si l S it h ” P•Build a “Simple Switcher” Power

Supply:•Small & light weight that mounts on the telescopetelescope•A single 12V power cord •Outputs

•5V for USB Hub (LM7805)•5V for USB Hub (LM7805)•8V for Canon DSLR (LM7808)•12V for Motorized Focuser or CCD Camera

STARFEST 2010 MODELSTARFEST 2010 MODEL

A single cord (12V) takes the place of 3 cords •Inexpensive ($30 - $40) including plastic box,Inexpensive ($30 $40) including plastic box, switch, fuse, connectors

•Uses LM78xx power supplies (approx. $ 1.50)•Parts stocked by most electronic parts storesy p•Easy to build

Complete plans available for download

Fabricate with Aluminum Using Common ab ca e u u Us g Co oWoodworking Tools

St f t 2011Starfest 2011

Machining Aluminum with a wood Routergwith Other operations and tips

with Gary Bennett and Dave Yates

C tti l tCutting a slot

1 Straight cutting bit1. Straight cutting bit 2. 2 fences to control your work3 M ltiple c ts take o r time3. Multiple cuts- take your time4. Listen to the machine-Beware heat build up

Cutting a Blind SlotCutting a Blind Slot

1. Straight cutting bit2. 2 fences to control your work3. Multiple cuts- take your time4. Listen to the machine-Beware heat build up5 Mark position on fence and part5. Mark position on fence and part 6. Stop bit before lifting part 7 Drill hole the size of your cutter to start slot7. Drill hole the size of your cutter to start slot

Cutting a Round OverCutting a Round Over

1. Round over bit with ball bearing2. Freehand is preferred3 Feed work against the direction of cutter rotation3. Feed work against the direction of cutter rotation4. A pass WITH cutter rotation to smooth the cut5. Carefully align height of bit to edge of table6 N ll t t f ll d t 3/16 Di t6. Normally one cut to fully round over up to 3/16 Diameter7. Over 3/16 radius (approx) use multiple passes raising bit

between cuts

Cutting a Large Round OverCutting a Large Round Over

1. Round over bit without ball bearing2. Part controlled and clamped in jig3 Feed work against the direction of cutter rotation3. Feed work against the direction of cutter rotation4. A pass WITH cutter rotation to smooth the cut (with care)5. Carefully align height of bit to edge of table6 O t i ibl thi t lti l t th6. One cut is possible on thinner parts- multiple cuts on other

parts7. Listen to the machine- back off and take smaller cut if the

router is labouringrouter is labouring

Inexpensive Aluminum tti hcutting chopsaw

1. Princess auto or Canadian Tire Mini cut off sawsaw

2. Metal blade- EBAY purchase about $103 Saw has built in clamp can swivel and lock3. Saw has built in clamp- can swivel and lock4. High RPM smooth cutting- Very compact5 L t th d th k T k ti !5. Let the saw do the work- Take your time!6. Can cut up to 2” diameter solid stock (2 cuts)

Metal cutting chopsaw made f t d d d hfrom standard wood chopsaw

1 Any 7-1/4” chop saw- Iron base is ideal1. Any 7-1/4 chop saw- Iron base is ideal2. Metal blade- Princess Auto3. 2 drill press 4” clamps –Princess auto- Inexpensive4 Clamps are bolted to base securely4. Clamps are bolted to base securely5. Let the saw do the work- Take your time!6. Can cut up to 2” diameter solid stock

S f7. Aluminum AND Steel! Very powerful and a real workhorse8. Clamp ALL your work- Both sides of cut!9. NEVER try to hold the part yourself- you are NOT strong

enough

SAFETY!SAFETY!

1 Clamp your work!1. Clamp your work!2. Wear safety glasses, gloves (as required)3. Take your time- don’t push the machine4 6061 T6 Aluminum cuts the best !4. 6061-T6 Aluminum cuts the best !5. Never try to hold the part with your hands with a chopsaw6. The saw is stronger than you! Respect it7. You do not need an expensive router or bits!8. Only Carbide bits with Aluminum – No Plain Steel9. Your shop should have a decent drill press

Wedge and Platform made with Router, chopsaw, T bl d D ill It CAN b d !Table saw and Drill press- It CAN be done!

OK MacGyver let’s get goingOK MacGyver, let s get going

QUESTIONS?QUESTIONS?