CupCake Challenge Hackathon

The folks over at Hackerspaces.org posted an international hackerspace challenge – ship a cupcake as far as possible and score points by completing a variety of tasks.  Sector67 accepted the challenge and used our newly created vacuum forming machine to crank out a form fitting cupcake shipping container.

The first step was to create a plaster positive of the bottom of the cupcake for vacuum forming.

While waiting for the plaster to cure, a positive for the top of the cupcake was rigged and attempted to vacuum form with 1/4″ polycarbonate:

Despite our best effort, we weren’t able to melt the polycarbonate with just the heat gun, so the kiln was rolled out:

After preheating the plastic it was returned to the vacuum table and heat was again added using the heat gun.

Conceding defeat after the plastic would not form, we moved on to a much thinner sheet of 1/8″ clear polycarbonate:

and were immediately met with positive results (pun intended).  By this point the plaster base was also ready to mold, so we again used 1/8″ polycarbonate plastic:

Having the two halves created, we were ready to go to the drill and bandsaw to clean things up:
Bolting things together:

Scott et al. handbaked some cupcakes using a special recipe to give enhanced rigidity without losing any taste or texture points 😉

Things were looking great when it was boxed up, hopefully it arrives intact at Jigsaw!

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Week in Projects

Andrew took some great pictures at the meeting!

Makerbot platform received a much needed upgrade of countersunk screws (yes seriously, they designed it with giant allen caps sticking up, I know, us too. . .)

Isthmus Engineering sent us another load of scrap materials and machine shop bits that were being discarded!  These guys are great, if you ever need equipment built that’s the size of your house, there’s no other choice out there 🙂

Dave broke out his toy helicopter sent to him from his brother on his birthday.  Note in this shot the laptop sitting just behind Dave’s right arm – that’s his brother on video chat watching Dave careen his birthday gift into the floor!  Technology is great 🙂

He then got down to real work: (Melamine sheet erases perfectly for anyone still wondering)

Peter tried out the hot air rework station to try reflowing the dreaded RROD on the Xbox360. The fix was initially successful but ultimately reverted to red after a few days. It will be returning shortly to try again at higher temperatures.
Interesting laptop power cord fix was spotted: (that’s a nail jammed into the insulation to make contact for the ground conductor)

Ann learned to solder and put together a micro-mouse soldering kit/toy.  We were initially a little underwhelmed by performance until the 9V battery was measured at 6VDC.  Swapping for a better battery led to insane speed being unlocked and chaos ensuing 🙂

Craig took out some aggression on a MagLite flashlight.  The batteries had been damaged when the flashlight was struck, leading to the leaking of all of the acid into the case which then sat idle for some time.  The entire interior of the flashlight was corroded into a giant ball.  He ended up using a 4ft solid steel prybar to get the last cell dislodged.  The flashlight amazingly survived with all critical features entirely intact – MagLite if you’re out there please send us a new flashlight so we can put this one out of its misery:

One cell free:
Cell two free:

Finally to free cell three:

We were fortunate enough to pick up four $5 computers from UW SWAP on Thursday, the machines are P4 2.8ghz with 1GB of RAM, seem to work perfectly after adding a hard drive and imaging them:

Joseph brought in his ultralight RC airplane.  We took advantage of the giant empty warehouse to take it for a test flight:

All this  RC plane and helicopter madness led to a rethinking of a junk RC helicopter, could it work as an RC paper airplane? Initial results are not good, but we’ll see how things go over the coming week, last seen this plane was under the hot-wire knife getting a new pink foam body!


Micah’s Focus, despite the drag posturing in this picture, has unfortunately thrown a few important bits in the transmission
so some time was spent removing it from the vehicle and getting a new transmission installed:

Peter spent some time patching up the hinge mounts on a laptop and disassembling a 900MHz cordless phone to explore the possibilities of a cheap Arduino integration for an RC project:

Lastly, a Ford Taurus received new lower ball joints, tie rod ends, brakes, and sway bar links:

Posted in News

Week in Projects

Despite the holidays there were a number of projects started this week:

Dave convinced Apple that his Hive and Seek word search game was suitable for market and is now available on the app store:

Justin stopped in to create a ski-waxing jig to make scraping in skis much easier:

Heather created some pillows for the couch with materials around the shop:

Too much time was spent reverse engineering and debugging some cheap wirelessly controlled outlets:

Scott put together a much needed set of wheels for the kiln to make it mobile:

A discarded bed frame provided the materials and will also be used to create a workbench in the welding area:

Sector67 receives a giant roadside sign:

TV was wall mounted, we’ll see how long it lasts 😉

Makerbot is printing a little better, still needs a bit more calibration work but there’s light at the end of the tunnel:

Other things accomplished:

  • Jon moved his CNC mill for the first time
  • Organizer for the lumber was assembled and put into use clearing a lot of floor space
Posted in News

Interest in Classes

Have you been browsing the classes and finding some pretty cool things you’d love to learn, only to find that no sessions are currently planned?  We’re trying to gauge demand for classes to figure out which ones should be held next or most of often, but have so far relied on verbal feedback.  Now, if you’re logged in using your forum account (link is in the far upper right), you can mark classes that you’re interested using the completely-ripped-from-f\Facebook-thumbs-up ( Interested, not like! ), and we’ll know which to hold next!

Posted in Website

2010 UW Photos of the Year – Sector67 Featured

Sector67 was founded by a $7,000 prize awarded through the Burrill Business Plan Competition at the University of Wisconsin. This image was captured by the UW photographer at the competition freezing in time the judges’ reactions to the concept of Sector67 and the opportunity available to the Madison community (full slideshow of 2010 photos of the year):

They don’t look to convinced to us at that moment, but they ended up liking us well enough to award 2nd place! Thank you Steven Burrill for sponsoring the competition and giving us the opportunity to exist.

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Thank You MAKE Magazine!

The holidays came a little early at Sector67 courtesy of MAKE Magazine! Following a tweet by MAKE magazine suggesting great gift giving guide for the hackerspace in your life we asked if they had anything they could send out to us to get the holiday season rolling, and they certainly did:

We received over 40 pounds of goodies, including issues of almost every MAKE magazine released, a home chemistry guide, Maker’s Notebooks, electronics kits, a great book called Introduction to Arduinos, and finally Making Things Talk.

We’d like to thank MAKE for supporting local hackerspaces around the world and inspiring people to get out and make the world a better place! Swing out to Sector67 and catch up on your MAKE magazine backlog or get some sweet experiments going using their great guides. Didn’t get everything you wanted for christmas but the parent slipped you some extra cash? Treat yourself over at the MakerShed 🙂

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Week in Projects

Final table assembly:

Prototype parts:

Co-working station – stop by during the day for maximum mobile enjoyment:

Web camera! Check out the about page for an image:

Laptop Repair:

Drill press return spring rework:

and some work to set up for the injection molding set up:

Flatt Cola:

A little late night CNC work:

Bicycle rack modification:

Makerbot calibration:

Soldering Class:

LCD Inverter Repair:

Posted in News

Pottery Wheel

Sector67 picked up a pottery wheel from Freecycle a few months back, it was basically a heavy table in someones garage for a number of years and in pretty rough condition.

After some more wire brushing and investing in a few quarts of oil based paints (and several days of multi-colored hands) it’s looking a little better and far more impervious to water:

We finally got a chance to break out the 50# boxes of clay and try throwing some clay:

Sometimes with varying success:

All in all, running a manual wheel is pretty fun, I can see where some people like an electric wheel, and despite all the technology running around the place I think this machine will stay firmly rooted in its old world ways 🙂

Posted in Hardware, News

LEGO Robotics Competition

Sector67 is excited to host the Madison Area LEGO Robotics Competition on April 9th, 5-8pm. We’ll be reusing FIRST robotics courses for a little regional competition of our own.

Rules are:

  • Using all of the Body Forward Course Rules
  • Only hardware limitation is you use a LEGO NXT or RCX Controller (must fit general regional competition requirements like size)
  • All software and hardware limits are off
  • Teams are any age/size

Sector67 will be hosting a few workshops on using the NXT kits between now and then, we’ll also have a limited set of LEGO robotics components you can rent to practice/use for the competition (deposit required and will be refunded on safe return of equipment). If you’ve been wishing FIRST was around when you were in school now’s your chance to give it a try, this is also a great opportunity for up-and-coming FIRST teams to get a little practice in before the real competition! We’ll see you on the plastic field of battle. . .

Posted in Hardware, News, Software Tagged with: ,

Sector67 Web Camera

Sector67 now has a DCS-920 web camera beaming live images from inside. Take a peek on the About page or below:

Posted in News

Quirky – Social Product Development

A friend sent over a link to Quirky, the idea is drawing up product concepts, voting them up high enough to get traction and ultimately taking products to market. If anything, it would be a great place to idea hunt 🙂 [Student competitors in various invention contests take note!]

Posted in News

Arduino Class Pictures

Markus was kind enough to shoot some great photos at the last Arduino class:

Have a look at the full set on Picasa.

Posted in Arduino, Hardware, News Tagged with: , ,

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