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.

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.

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.

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.

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.)

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.

My new grinder needed some task lighting for the grinding wheels. I decided to build a dedicated lamp for each side, controlled by the grinder power switch. This worked in perfectly with my latest obsession, I mean interest, which is LED lighting.

Any trained machinist will tell you that a drill press with a cheap jig is no substitute for a proper lathe. I'm not a trained machinist, so now that I've said that, let's get on to accomplishing something interesting.

In my quest for high-efficiency lighting, I came across a new idea for small household lights.

In our bathroom, there are two sconce lights (one on each side of the mirror) in addition to the main lights over the top of the mirror. The side sconce lights are not really necessary for adequate lighting, but they look nice and add some visual charm to the mirror. Therefore I saw them as good candidates for lower-energy substitutes.

Compact fluorescent light bulbs, or CFLs, have been generally available and affordable for consumers for quite a few years now. I've been using them for about ten years, and they have steadily improved during that time. Needless to say, they aren't perfect, but there are many ways to use them successfully.

It is not simple to make a new kind of light bulb which can replace the simple incandescent bulb in all situations and still provide significant energy savings. Some tradeoffs are necessary.

I have an old laser printer which does not have a decent standby power-saving mode.  I built a computer-controlled power switch for it, so the computer turns on the printer when there is a print job, then turns it off again later.

Many woodworkers have dust collection systems, which use suction and large pipes and hoses to collect sawdust and other particles from power tools.  For the hobbyist, these systems can be affordable, below $1000 for a decent system.  Naturally, I therefore wondered what I could accomplish with my old shop vacuum, some junk from the garbage can, and about 20 bucks.

As a handyman and hobbyist, I find there are many everyday plastic objects that can be used to make interesting things.  Some of the most common useful plastics, such as high-density polyethylene (HDPE) and polypropylene (PP) just cannot be glued.  But they can be welded with hot air.  You may be surprised at what you can make with an old plastic bucket and a heat gun from the discount tool store.

 

I recently borrowed this book from a friend, and found it very useful. I was already a fairly fast reader, but I had never investigated "speed reading".

I found that by following these techniques, not only did I read faster, but my comprehension improved. The book covers speed reading techniques and also related improvements in study skills for students.

After I made the mounting bracket, then I proceeded to create the blade guard and splitter.