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Broken USB Lamp Saved with a Bit of Woodworking

Por: Tom Nardi
2 Enero 2025 at 06:00

For many of us, when we think of creating a custom enclosure, our minds immediately go towards our 3D printer. A bit of time in your CAD program of choice, and in an hour (or several), you’ve got a bespoke plastic box. A hacker’s dream come true.

But extruded plastic is hardly perfect. For one thing, you might want a finished piece that looks a little more attractive on your desk. Which is why we appreciate this quick hack from [Tilma]. When faced with a broken LED light and minimal equipment, he decided to transplant the repaired electronics into a scratch-built wooden frame that not only looks better than the original, but is more functional.

Fitting the LED board into the new wooden frame.

The video starts with a teardown of the original light, which was a flexible affair meant to plug directly into a USB port. [Tilma] found that the reason it failed was because of a broken solder joint, presumably due to repetitive motion. Of course, to find this failure he needed to cut away the rubbery sleeve it was encased in, hence the need for a new home.

After tacking on some longer wires to the driver board, [Tilma] connected an external button that he thought would last longer then the stock membrane affair on the PCB. Once it was confirmed that the light worked with the modified electronics, the rest of the video covers how the wooden components were assembled using hand tools. Compared to the high-tech gadgetry we cover on a daily basis here, there’s something refreshing about seeing a person working with chisels, clamps, and rulers.

We think the final result looks quite nice for as simplistic as it is, and is unquestionably more practical than a weird little light bar that sticks out from your USB port. If you’d like to add a bit of woodworking to your bag of tricks, [Dan Maloney] covered some of the basics for us several years ago.

Creating a Signature Wood Joint

1 Diciembre 2024 at 21:00
A pair of hands hold two dark brown boards perpendicular two each other on a light brown benchtop. There are two light brown oval dowels in the end of one board that then project toward holes in the opposite board. Circular holes in the oval dowels are visible perpendicular to the second board, and will match up with holes in the board once pressed in. A cylindrical dowel is laying next to the joint and will be placed into the circular holes once assembled.

We really love when makers make their construction techniques evident in an aesthetically-pleasing way, and [Laura Kampf] has created a clever joint that reveals how a piece is made.

[Kampf] is a big fan of using her domino joiner, which is similar to biscuits or dowel joinery, but she didn’t love how it hid the construction of the joint. She first figured out an “off label” use of the joiner by running it from the outside of the joint to show the exposed domino from one end.

Building on the concept to show an interesting contrast on both sides of the joint, she drilled a hole perpendicular the domino and placed a dowel through it, creating a locking joint. The choice looks great once a finish is applied to really accentuate the contrast, and another bonus is that if glue is only applied to the dowel and domino, it becomes trivial to separate the joint if needed by drilling out the dowel.

If you’d like to see some other interesting ways to join wood, how about this laser-cut wedge tenon, soda bottle heat shrink, or this collection of CNC joints.

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