Family & Friends Projects

Tesla Pendant for Tanya, 2022

I had started the design of this pendant a couple years ago when we had found this stunning blue London Topaz stone at a "rock swap" in Maine on one of our family adventures. I have wanted to design and make a custom gold pendant for quite a while, and this was a way to incorporate the stone into something for my wife Tanya, who is a big fan of Tesla. I started by measuring the stone and creating a CAD model of it. I then took a picture of the "T" logo on the Frunk (hood) of our Model 3 Performance. I imported the picture into SolidWorks and traced out the logo to scale. I slightly widened the lower section of the logo to accommodate the setting for the stone.

It then sat for a while (about 2 years), as I was too cautious to trust sending the CAD model to Shapeways or another online 3D printing house to have it made from 14K gold, as from those services you tend to "get what you get". Then in July of 2022, while on Twitter, I found Annie Salter, a fine jeweler and Tesla fan. I noticed that her Twitter picture was a Tesla pendant that she had made that was similar to the one I had designed. I contacted her and found she also lived here in New Hampshire, and was interested in collaborating on the project.

Annie had a trusted contact who could 3D print the pendant in wax, then do an investment casting of the pendant in 14K gold. Annie then used her skills to adjust the setting for the stone in the pendant, and polished it to a bright shine.

On 12/3/2022, Tanya and I met with Annie, and got to know her over dinner. She delivered the pendant, and we are already talking about future projects to collaborate on.

My daughter Lauren's Projects

While this website is slightly out of date (she is working on a new website) it still shows several of the projects my daughter Lauren has come up with over the years. Most of these projects were created for the Young Inventor's Program, a K-8 national program, or for many of the various Maker Faires we have attended.

My son Sean's Projects

This is my son Sean's website, and shows many of the crazy ideas we have worked on together. Like his older sister, several of these projects were for either the Young Inventor's Program, or were for Maker Faires, however many of them are just for fun. Sean's most famous invention (so far) is his paper airplane launcher, seen above when he appeared on "The Tonight Show starring Jimmy Fallon" "Fallonventions" segment back in 2015.

Laser-cut Earrings for Tanya

Tanya had commented on some cute 8 bit heart shaped images, so I turned them into earrings by generating the shape in SolidWorks, creating a drawing, saving the drawing as a PDF, opening the PDF in the Glowforge web app, then finally laser cutting the shapes from 3mm red acrylic. The wire is silver wire, and the rings and hooks were sourced from Amazon.

Next up is the whole series of PacMan figures, and likely a set of 8 bit cherries.

I formed the "staple" shaped wires connecting the upper bar of the "T" to the lower section using a great set of pliers from Micromark, which are perfect for this kind of work:

https://www.micromark.com/Metal-Forming-Pliers-Set-of-4

Centipede Console Protector

We’ve been having a great time learning how to use our new Glowforge laser cutter.

For Christmas 2018, I had purchased Tanya an Arcade 1UP Centipede 3/4 sized arcade. It gets used quite a bit, and has been showing some wear on the control panel around the buttons and trackball. Recently Tanya mentioned that she hasn’t been playing it as much as usual as she didn’t want to damage the graphics around the buttons and trackball any further. Glowforge to the rescue!

I started by removing the control panel and 3D modeling it in SolidWorks. Once I had duplicated the outer profile and added the holes for the speaker, track ball, buttons and switches, I created a 1:1 drawing in SolidWorks on a custom sized sheet of paper (instead of 8.5x11, 11x17, etc.) that is the same size as the bed of the Glowforge. I saved the file as a 1:1 PDF file, and opened that in app, dragged it and dropped it in the very middle of the material. This is a tight fit, and was just inside the cutting envelope of the machine. I should have done this when it was new…

Drift Trike built with Sean

When my son Sean was assisting me with the trash at the town transfer station, he saw a BMX bike and mentioned that he wanted to build a drift trike like Colin Furze (original video - newer video). So, we grabbed the bike and some scrap steel and brought it home. I had squirreled away an 8 HP snowblower engine, a centrifugal clutch, some #35 chain, a sprocket and a 1" barbell shaft thinking that someday we would build a go cart - but we already have two go-carts with suspension and several other toys. When we got home, Sean grabbed the cutoff wheel and quickly hacked apart the bike frame, leaving the front end, neck and larger lower down-tube. We did some preliminary layouts of how the parts could be arranged on wood blocking, and got to work. We found that the original down-tube on the bike frame was at the wrong angle, and didn't look that great. We chopped that off too, and used a larger diameter thicker wall tube as the new down-tube. We made some pegs to rest your feet on on the front axle, and installed the twist throttle. The hubs, wheels, tires and plastic sleeves arrived, so we trimmed the rear axle and installed those parts.

Remaining work to do:

  • Finish the frame design and weld together - DONE 5/6/2020

  • Make supports to mount the seat- DONE 5/6/2020

  • Cut keyways in the shaft for the sprocket and hubs - DONE 5/10/2020

  • Reconnect the brake in the front - DONE 5/10/2020

  • Design and fabricate bits for throttle connection to engine - DONE 5/17/2020

  • Install kill switch- DONE 5/17/2020 (replace - broke the first day using it).

  • Fire it up and test ride it!- DONE 5/17/2020

  • Design fabricate and install a rear brake & Improve front brakes - DONE 6/18/2020 Converted to Disc Brakes, front and rear. Front wheel is rear BMX bike wheel with a machined aluminum adapter to mount the rotor in place of where the ratcheting mechanism was under the rear sprocket. New side plates were fabricated to mount the caliper, and the front fork axle mounts were widened to accommodate the wider hub.

  • Make a chain guard

VID_20200518_183035534.mp4

Operational Drift Trike

On 5/17/2020, we connected up the throttle cable and the kill switch and went for a quick test ride before it was completely dark outside. This thing is SO MUCH FUN! Thanks for the inspiration Colin Furze!

The brakes require MAJOR upgrades - front work (sort of) and there are no rear brakes at the moment. We also need to strip it down and paint it.

Funny source for the metal for the frame - It was the treadmill that Tanya and I had for years. She used it quite often until it started to fail, and I repaired it a few times. It finally was just always in the way and needed repair.

New Fire Pit built with Lauren

When my daughter Lauren was assisting me with the trash at the town transfer station, she spied some heavy metal grating on the scrap pile. I saw a stainless steel washing machine drum and mentioned that I always wanted to make one of them into a fire pit. So, we grabbed the metal along with a rectangular frame of 1" steel angle from the pile and brought it home. The following weekend, I removed t he plastic parts from the ends of the drum while Lauren trimmed the steel grating. Unfortunately, we had two pieces, neither was large enough alone, so we marked the diameter on the two pieces and Lauren welded the grating into one circular piece that would form the base of the fire pit. She used the metal cutting bandsaw to trim the angle steel frame to fit under the bottom lip of the drum, and used the extra end bits as legs, welding them onto the base. We then bolted through the grating to the frame, clamping the flange of the drum in place. We positioned the fire pit in the center of the old playground area, which is about a 6" depth of pea stone in an area 25' square. The legs are easily buried in the pea stone with a decent air gap at the bottom.

That night we lit the fire for the first time, and wow, does it work well! It burns hot and fast, something that works well for us in a fire pit. It allows us to be outside for an hour or two, and not have to babysit a pile of wood that is slow to burn down. I have some heavy stainless steel mesh that I may use to make a lid for the fire pit in the future. Also on the to-do list is to strip and repaint the metal chairs...

Learning to solder kit

I recently collaborated with a friend of Rick Schertle to help develop this learning to solder kit, featuring a programmable LED array. I helped with the board layout, and also designed the easily 3D printed case and also the easy to customize laser cut front panel cover. The device is programmed using a phone app through the headphone port.

Prototype for a friend

In 2016, I had assisted a friend with designing and prototyping a battery charger stand for a start-up business. The finished product is shown above. I designed the molded plastic base, aluminum covers, wire management, and sheet metal lower cover. I also arranged the production of the parts and built the first couple devices to verify the design. Several of these were made for a trial run for their customer.

UPDATE 3/20/2020:

These chargers and several batteries were donated to a hospital in NYC in one of the hardest hit areas of the Corona virus outbreak. They are being used by patients to charge their electronic devices so they are able to keep in touch with their loved ones. Story about it here:

https://www.manhattantimesnews.com/ipads-for-patients-ipads-para-pacientes/

Quick wheelchair ramp build

For a last-minute Sunday road trip that included my mother-in-law (who is wheel chair bound), I took a few hours on Saturday and built this folding ramp. It's 14" high to match the height of the running boards on my truck, and allows her to easily transfer from her chair to the front seat. It has a horizontal 30" x 47" platform and a 30" x 47" folding ramp. I used the material I had on hand, some 2" steel angle, some slotted hole strut channel, and plywood that was left over from previous projects. The steel parts were welded together, the decking was added, and the hinge pin holes were drilled. The ramp section folds flat onto the top platform, and it easily fits in the truck bed. It turned out better than expected for a 4 hour hack build on a Saturday. It helps to have "stock" of stuff to pull from when making crazy projects like this.

In hindsight, I should have added a couple wheels to make it easier to get in position. Also a coat of paint would help make it look a bit better. Ideas can always be improved...