Alan Millar's personal website

Fluxing Zinc in the Backyard Foundry

According to the backyard foundry experts, the most useful casting metal that's even easier to melt than aluminum is zinc. It melts around 420°C/800°F, so you can even melt it on a hot stove. It casts harder than aluminum for better wear, and zinc/aluminum alloys can approach cast iron in strength and durability. Sounds great! All you have to do is buy some nice clean zinc ingots, and... Whoa nelly, what?! Buy ingots? I'm way too cheap-@$$ frugal for that. We're going to melt our own. Easy as pie, right? Turns out that melting zinc is easy. Cleaning it? Not quite so much.

Backyard Aluminum Melting

Let's melt metal in the backyard!

Yeah, that teensy-weensy little pool of molten metal in arc welding was cool, but it was time to move up to the next level. A big glowing pot full of silver liquid awesomeness. Oh, yeah.

XMMS now Audacious

I've always liked XMMS as a music player program on Linux. It had enough features, but the basic interface was always simple enough to just work. Unfortunately, it is not maintained any longer, and in my latest Ubuntu upgrade to version 8.10, I found it was no longer included or supported.

The XMMS project continued with a successor, XMMS2, but it is much more than just a simple audio player. I looked at it and got lost fairly quickly. I just wanted something simple like the original XMMS.

Art deco LED desk lamp

I built a stylish energy-efficient desk lamp, entirely from scratch. I have always enjoyed Art Deco and Machine Age industrial styling, and was inspired to use it for the lamp when my son and I were watching Batman, the Animated Series. A desk lamp worthy of Wayne Manor was in order.

iMac intel fan stuck on

We had a short power outage, and when the power resumed, the fan in our iMac (intel core duo) was stuck on full speed. It sounded like a jet plane. I waited a minute or two for it to slow down, but it didn't stop. Even rebooting didn't affect it.

After some Internet searching, I found that there is a chip which controls the fans, which can get stuck like this. Fortunately it can be reset also.

Halloween 2008: Crazy Aviator Costume

Here is my crazy aviator costume from Halloween 2008. I was inspired by a recent steampunk ornithopter picture.

I made the aviator helmet using a leather jacket from the thrift store and the goggles from last year's explorer costume. I made the pattern for the helmet by taping newspaper to my head. Then I cut out pieces from the jacket to match and sewed them together. The copper buckle is household solid electrical wire.

Halloween 2007: Crazy Explorer


Here is my crazy explorer costume from Halloween 2007. I was inspired by old pictures of European explorers from the late 19th and early 20th century. Finishing touches included a pith helmet with goggles, a latern with a working flashlight in it, and a ridiculously oversized gun.

Flat panel TV swing-arm mount

Jessica bought a flat panel TV, and wanted to attach it to the wall with some sort of swing-arm mount. The prices at the store were outrageous. Armed with my moderately-trustworthy arc welder and couple of discarded bed frames, we set out to construct one ourselves.

Baldor Grinder Restoration

I received a Baldor metal grinder with 10-inch wheels, on its own pedestal floor stand, discarded from a school metal shop program. Several owners before me did not know what to do with it, mainly because the motor is wired for three-phase industrial power which is not found in U.S. residential homes. My job was to fix it up and get it working.

There were two major tasks to the restoration: cleaning/repainting, and making the three-phase motor work.

3-phase motor static phase converter

I received a Baldor metal grinder with 10-inch wheels, with a motor wired for three-phase industrial power. Three-phase power is not provided in U.S. residential homes, so I needed to power it from normal single-phase power. My solution was to build a balanced static phase converter, requiring only a few relatively inexpensive capacitors. (Much less expensive than the nuclear reactor I was considering.)

Professor Calorium's Pyroelectric Metalurgical Liquefaction Apparatus

The handle broke off my manual lawn aerator. It had been welded in place, and since I have an arc welder, I figured I should weld it back on. This was the first time I attempted to arc weld something with a real purpose to it. There were a few details to work out, such as the fact that I don't know if the welder works right, and I don't know if my welding rods are any good, and what was the other one? Oh yeah, I don't know how to arc weld. Well OK then, time to get started.

GPS for OpenStreetMap

I bought a cheap GPS on EBay. I got a Palm Vx with a Magellan GPS Companion attachment for ten dollars. By PDA standards the Palm Vx is completely obsolete, but it works fine as a GPS data logger.

OpenStreetMaps

Mapping Hacks
cover
Amazon | Half.com
Powells | BookSense
I've recently come across two interesting projects and web sites: openaerialmap.org and openstreetmap.org. These two projects are efforts to collect and share freely-available map information.

Canadian lynx

Anne and I saw a Canadian lynx outside a local veterinarian's office. He was waiting in the car with his owners for the vet, which handles all sorts of animals besides just cats and dogs. The owners of the lynx have an exotic animal refuge.

This cat's name is Tucker, and he was quite friendly. He let us pet him and stroke his very soft fur. He has a pink nose just like a house cat, and his paws were HUGE.

The owners take him everywhere, and I would too if I had one. What a fabulous, beautiful animal.

Restoring equipment labels

When I fixed up an old drill press, I found that the switch plate for the on/off switch was fairly worn. The original paint and lettering was worn away, so that the start/stop wording was almost unreadable. Even though I am clever enough to figure out that the big red button means "stop", it needed a clearly readable switch plate label.

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