Deconstruction - Rabbit Hole

This Instructable submitted by the Rabbit-Hole Maker Space as part of the Instructables Sponsorship Program.

As we start this evening - the whiteboard comes out!  The theme, as mentioned before is the Zombie Apocalypse!  Some of our initial ideas are:

Bike trailer

Inspiration: One of our hackerspace members bikes everywhere.  He needs a bike trailer to haul his groceries and zombie weapons.
Materials: PVCS, Rope, Bushings, Axle, Metal bar stock, rubbermaid tote, secondhand bike wheels.

Solar Powered Lantern

Inspiration: During the tsunami that hit Japan, the Tokyo hackerspace made solar powered lanterns and handed them out while power was still down.
Materials: Old busted lanterns (camping lanterns/nonworking solar powered lanterns)

Can Crusher

Inspiration: Tim's recycling folks stopped picking up recycling.  So!  Since he has to bring it in, it may be worth it to crush and decrease on space taken up. 
Materials: Old snowblower tires, old garage door opener, garage door sensor, old dartboard for its LED displays and sound chip.

DIY water filter

Inspiration: During the zombie apocalypse, you're going to need food and water - but to have potable water, you need a water filter!
Materials: Charcoal from the fireplace, sand, old rubbermaid container, unused tubing

Final Video! 

2-3 hours into the design/planning process.  Project Updates:

Bike Trailer

Tim and Peter are adapting wheels to sprockets.

Solar Powered Lantern

A few of the frame pieces have been cut and we're currently determining whether the broken solar lantern cells (or NiCad batteries) work properly.

Automatic Can Crusher

Here're the first cuts and holes for the frame of the can crusher.  We've also ensured that the garage door opener works!  Plans are underway to dismantling the dartboard and its chips as well.

4 hours into the design/planning process.  Project Updates:

Bike Trailer

Tim and Peter are (still?) adapting wheels to sprockets.

Solar Powered Lantern

So we have 5 solar cells and 3 rechargeable 1.5v batteries.  After measuring, have 3 functional 1.5v batteries, and according to our voltmeter, about 5v of power.

Automatic Can Crusher

We got more of the setup...set up!  One problem we're coming across is that the cans need a little more push behind them for them to be properly crushed by the wheels...Any suggestions?
We are also taking apart a paper shredder to see if the shredder parts can catch onto the cans to pull them in

6 hours into the design/planning process.  Project Updates:

Bike Trailer

PVC Pipes have been cut - part of the frame has been assembled and part of the yoke and axle are MIA!

Solar Powered Lantern

The wooden frame + rice paper is almost done!  The pieces are held with countersinked screws.

Automatic Can Crusher

So in the last two hours, we've solved the can - biting portion.  Using PVC pipe to properly align the cans, the tires can grab onto them and pull them in to start crushing the can.

No luck on the paper shredder, but lots of mini shuriken that could be used against zombies!

7-8 hours into the design/planning process.  Closing time for day 1 - Project Updates:

Bike Trailer

Team Asleep!

Solar Powered Lantern

The wooden frame is just about done - we used 1"x2"x8' wood stock and made the frame based on some googled images of Japanese lanterns.  Using old chinese paints, I decided to add a little rabbity flair!  2 of 4 panels done!

Automatic Can Crusher

Team Asleep!

After a night of relatively restless sleep - we're back at it! 

Project Updates:

Bike Trailer

Jon's thinking of a new potential design for the bike trailer - ideas forthcoming!

Solar Powered Lantern

I'm going to keep working on the panels - 2 left!

Automatic Can Crusher

Arduino incorporation is being looked into!

16 hours in! 

Project Updates:

Bike Trailer

We're trying to figure out how to attach a post to his bike frame that work with the nuts and bolts we have around the house.  Hmmm....

Solar Powered Lantern

I'm going to keep working on the panels - 1 left!

Automatic Can Crusher

They're trying to figure out how to make it so that the can chute is adjustable but stable...

18 hours in! 

Project Updates:

Bike Trailer

Guys are off at a hardware store finding some bolts that'll work since none of our old ones work.

Solar Powered Lantern

Panels all painted!

Automatic Can Crusher

They're trying to figure out how to make it so that the can chute is adjustable but stable...

20 hours in! 

Project Updates:

Bike Trailer

Pieces are being cut and fitted around the bike frame for the trailer "hitch"

Solar Powered Lantern

Panels all painted!  Finished up gluing two painted panels to the frames, and cut the others to fit the remaining frames.

Automatic Can Crusher

Bolts are being readjusted to fit the chute.

22 hours in! 

Project Updates:

Bike Trailer

Pieces are being cut and fitted around the bike frame for the trailer "hitch"  Had to use a grinder and bandsaw to shape the stock metal piece that fit around the frame.

Solar Powered Lantern

Added external wood pieces to place battery holders and solar panels on.  Wiring has also started for the circuitry!

Automatic Can Crusher

On hold while folks have dinner with their significant others!

24 hours in! 

Project Updates:

Bike Trailer

From what I understand, the guys are busy welding the frame of the bike trailer? Maybe?  As soon as I can get better updates, I will let you all know

Solar Powered Lantern

The wiring has been done up by Ken and the battery clips all installed.  Battery packs are currently being charged.  The only problem we've had is that it seems that two of the batteries are not working properly.  But since at least one works, we have proof of concept!!  (EDIT: We excitedly found out that TWO of them work...though one for only a brief second)

Automatic Can Crusher

Tim and Will are trying to get the garage sensors (that will probably count the number of cans being crushed) working with their Arduino.

26 hours in 

Project Updates:

Bike Trailer

The guys are finally back from their welding adventures...and it looks like the wheels are attached to the trailer chassis!

Solar Powered Lantern

So we've put the frame together with nails and the solar panels as well as the batteries are attached to the frame.  We've replaced the NiCd batteries with NiMH batteries and are seeing whether they work with those or not!

Automatic Can Crusher

Tim, Matt, and John V. are working on the frame that will hold the can crusher above the trashcan - debates abounding about 3 legs vs 4 legs for stability!

28 hours in - deliriummm! 

Project Updates:

Bike Trailer

Jon's busy putting together the trailer and making sure everything fits properly

Solar Powered Lantern [Done!]

So two of the charging circuits don't seem to be working but the one that does work gives off a bit of light that's diffused throughout the lantern!  Interestingly, the two that did not work had the same circuit.  So it may just be that particular circuit. Proof of concept = success!

Automatic Can Crusher

The frame is still being worked on - and it looks like they've incorporated the garage opener on it.  The old garage door chain is connected to one of the tires that is responsible for crushing the cans.  Tim's working on programming the Arduino for the sensors they want to put onto it. (EDIT: Seems like it's working! We just need to finish the frame!)

29-30 hours in - are we still awake? 

Project Updates:

Bike Trailer

Jon's busy putting together the trailer and making sure everything fits properly - mostly the rope webbing for holding gear.

Solar Powered Lantern [Done!]

Our hallway isn't well lit - but as soon as you bring the lantern into the hallway, it turns on!

Automatic Can Crusher

The frame has pretty much been finished!  We've found an angle that it works at and have set up supporting structure.  It even has its own skull :)  Left on this project are the Arduino sensor programs!

38 hours in!  I really hope I'm keeping proper track of these hours haha.  

Project Updates/Current Status:

Bike Trailer

It looks like the next step for this may be taillights and figuring out how to connect it to the bike!

Solar Powered Lantern [Done!]

The lantern is still functional even after a night of hardcore charging! (I always worry about the circuit)

Automatic Can Crusher

Tim is probably working on the Arduino code this morning and Matt is working on installing a 3way switch so that we can reverse the direction of spin (maybe for projectiles?)

The clock is ticktocking down!!  

Project Updates/Current Status:

Bike Trailer

It looks like the next step for this may be taillights and figuring out how to connect it to the bike!

Solar Powered Lantern [Done!]

The lantern is still functional even after a night of hardcore charging! (I always worry about the circuit)

Automatic Can Crusher

Tim is probably working on the Arduino code this morning and Matt is working on installing a 3way switch so that we can reverse the direction of spin (maybe for projectiles?)

42 hours in!   

Project Updates/Current Status:

Bike Trailer

We've figured out a ghetto-style ball and joint mechanism to hook up the bike trailer to the bike!  It involves a lot of washers and nuts (no pun intended).

Solar Powered Lantern [Done!]

The lantern is still functional even after a night of hardcore charging! (I always worry about the circuit)

Automatic Can Crusher

Tim and Matt are cobbling a 7 segment LED driver and learning about the Arduino in the mean time!

44 hours in!   We're coming down to the last hours!  

Project Updates/Current Status:

Bike Trailer [Done!]

I think we're done with this project!  If we get ambitious we might add LEDs but for now, woohoo!

Solar Powered Lantern [Done!]

Automatic Can Crusher

Tim and Matt are still working on the code and I think getting digit 9 to come up :D Learning Arduino programming on the fly!  Peter's working on getting the IR sensors to work properly so we can get can counting set up.

46 hours in!   Wheee!  

Project Updates/Current Status:

Bike Trailer [Done!]

Solar Powered Lantern [Done!]

Automatic Can Crusher

Tim, Matt, and Peter have the can counter set up and are seeing if they have enough time to include a dancing robot!  We all need dancing robots. (It actually looks a lot like the Instructables robot!)

Whattttt - won't be long before we close up this 48 hour shop!

Project Updates/Current Status:

Bike Trailer [Done!]

Solar Powered Lantern [Done!]

Automatic Can Crusher

Tim, Matt, Will and Peter have put together the epic can crusher - RECYCLOTRON - complete with dancing robot!

Parts list for The Recyclotron Can/Brain Crusher and Zombie Warning System:

Main Can Crusher Portion:

2 circa 1985 Sears Craftsman pneumatic snow-blower tires
1 used Chamberlin 1/2HP Garagedoor opener
1 3/4" by 4' stock steel rod from Fleet Farm ($7.99)
1 3' chunk of 3" ID pvc
Misc pile of reclaimed 2x4x4'
Misc screws and carriage-bolts
1 standard 3-way light switch so motor can go fwd and backward
Chain from Garage Door opener
Rear 7 speed cassette (welded to steel rod) from a donated bicycle

Bonus Electronics:

1 set of garagedoor opener sensors and wires
1 Arduino Uno, reads door sensors display the count of cans crushed, and control the robot and sound effects
1 Sportcraft electric dartboard deconstructed (or scavenged) for the electronic components including 7 segment LEDs and sound board. ($2.50 from Goodwill)
1 broken usb powered dancing robot (arduino causes it to dance on every 12th can)
1 breadboard
Misc transistors, resistors, LEDs, 2 74HC595 shiftregisters and 1 relay
1 rail section from the garage door to hold the poster-board with breadboard/arduino mounted on it
Discarded power adapters (wall-warts) to power electrical components
Glue, zip-ties, solder, blood, sweat and duct tape
Only paid for 2 items, the axle was $7.99 and the dartboard was $2.50.

Parts list for The Foraging Bike Trailer:

2'' PVC scrap pipe.
Misc. PVC joints
50' nylon rope.  $1.99
2 donated 20'' bicycle tires
5/8'' steel rod axle
Shims to match axle to bicycle bearings
lock collars to hold wheels in place
1 plastic tub
3 flat bungee cords
Misc. bolts, nuts, and washers
1 bicycle LED blinky light

Parts list for The Solar Powered Lantern:

1x2"x8' wood stock, plywood scraps
Broken solar lantern circuitry from garden lamp
Paper - chinese painting paper/rice paper or newspaper if you want
Screws, glue, nails

Additional Details for Bearing Shims on Bike Trailer:

2x 1/2" "black" pipe nipples 6" long
2x 3/4" "black" pipe nipples 3" long
2x 1/4"-20 bolts 1.5" long
2x 1/4"-20 nylock nuts

Procedure:

Chuck the 1/2" plack pipe nipple in a lathe with 5" sticking out.
Boar the center of the pipe out to just under 5/8". The pipe ID is 5/8" or just over but there is a weld seam that needs to be cut down to fit properly.
Next turn the outside diameter down to 0.785" (or 0.005" under the ID of your wheel bearings) for a length of 3.5"
Cut off the pipe nipple to 4" long.
repeat the above steps for the second 1/2" pipe.
Next cut 2 rings out of the 3/4" pipe 1/2" wide.

Assembly:

The 1/2" pipe should be a slip to pound fit over the 5/8" axle.
Install one 1/2" pipe shim with the "shoulder" in. Pound on till non shoulder end is flush with the end of the rod.
Next install the axle though the 5/8" holes in the PVC T -> PVC axle tube -> second PVC T.
Install the second pipe shim again with the "shoulder" in (180 deg from the other end of the axles). Push the shim on until it is tight against the PVC Ts and the axle cannot float sideways in the PVC frame.
Next install the wheels on both pipe shims until the inside bearing is flush against the shoulder on the pipe shim.
Install the 3/4" pipe rings so they are flush against the outside wheel bearing.
Finally drill a clearance hole for the 1/4"-20 bolt all the way through the 3/4" ring -> 1/2" pipe shim -> 5/8" axle -> 1/2" pipe shim -> 3/4" ring. Install the 1/4"-20 bolt and nylock nut.

Arduino Code for dancing robot and can counter:
// Deconstruction shift register 8 LED segment.

//Pin connected to ST_CP of 74HC595
int latchPin = 8;
//Pin connected to SH_CP of 74HC595
int clockPin = 12;
////Pin connected to DS of 74HC595
int dataPin = 11;
// Pin for LED.
int ledPin = 9;
// Pin to activate the robot.
int robotPin = 10;

// Pin for analog input from sensors
int counterPin = 0;


byte dataArray[10];
byte numbers[10];
int counterState = 0;
int counter = 0;
int last = 0;


void setup() {
  //set pins to output so you can control the shift register
  pinMode(latchPin, OUTPUT);
  pinMode(clockPin, OUTPUT);
  pinMode(dataPin, OUTPUT);
  pinMode(ledPin, OUTPUT);
  pinMode(robotPin, OUTPUT);
  pinMode(counterPin, INPUT);
  Serial.begin(9600);
 
  // Arduino does not have a way to write binary, so use HEX.
  //                   //G
  dataArray[0] = 0x00; //00000000
  dataArray[1] = 0x01; //00000001 = A
  dataArray[2] = 0x02; //00000010 = B
  dataArray[3] = 0x04; //00000100 = C
  dataArray[4] = 0x08; //00001000 = D
  dataArray[5] = 0x10; //00010000 = E
  dataArray[6] = 0x20; //00100000 = F
  dataArray[7] = 0x40; //01000000 = G
  dataArray[8] = 0x80; //10000000
  dataArray[9] = 0xFF; //11111111
 
  numbers[0] = 0x3F;  //00111111
  numbers[1] = 0x06;  //00000110
  numbers[2] = 0x5B;  //01011011
  numbers[3] = 0x4F;  //01001111
  numbers[4] = 0x66;  //01100110
  numbers[5] = 0x6D;  //01101101
  numbers[6] = 0x7D;  //01111101
  numbers[7] = 0x07;  //00001111
  numbers[8] = 0xFF;  //11111111
  numbers[9] = 0x6F;  //01101111
}

void loop() {

  counterState = analogRead(counterPin);
  //Serial.println(counterState, DEC);
 
  if (counterState < 30) {
    digitalWrite(ledPin, LOW);
  } else {
    digitalWrite(ledPin, HIGH);
  }
 
  if ((counterState < 30) && last > 30 ) {
    counter += 1;
    if ((counter % 12) == 0) {
      // Activate robot.
      //Serial.println("Activate Robot");
      digitalWrite(robotPin, LOW);
    } else {
      digitalWrite(robotPin, HIGH);
      //Serial.println("Robot Deactivated");
    }
  }
 
  digitalWrite(latchPin, LOW);
  int tens = counter % 10;
  int ones = counter / 10;
  // shift out the bits:
  shiftOut(dataPin, clockPin, MSBFIRST, numbers[ones]);
  shiftOut(dataPin, clockPin, MSBFIRST, numbers[tens]);
 
  digitalWrite(latchPin, HIGH);
 
  last = counterState;
  //delay(100);
}