car hacks

441 Articles

A Simple Air Suspension Demo With Lego Technic

January 25, 2023 by 18 Comments

The most common suspension systems on automobiles rely on simple metal springs. Leaf spring and coil spring designs both have their pros and cons, but fundamentally it’s all about flexing metal doing the work. Air suspension works altogether differently, employing gas as a spring, as demonstrated by this simple Lego build from [JBRIX]. 

The suspension system is employed on a Lego Technic car, with a relatively unsophisticated design. The car has no real form of propusion, and serves solely to demonstrate the air suspension design. They may look like dampers, but the system is actually using Lego pneumatic pistons as springs for each wheel. The pistons are connected to the upper control arm of a double wishbone suspension setup. Each piston is pneumatically connected to a main reservoir. With the reservoir, and thus the pistons, pressurized, the suspension system can support the weight of the car. If a bump perturbs a wheel, the piston compresses the air in the system, which then returns the piston to its original position, thus serving as a spring. If the reservoir is vented, the suspension collapses. Air springs on real, full-sized automobiles work in basically the same way. However, they usually have a separate reservoir per corner, keeping each wheel’s suspension independent.

Overall, if you’re working on some kind of Lego rambler, you might find this suspension concept useful. Alternatively, you might simply find it good as a learning aid. If you want to learn more about oddball suspension systems, we can help there too. Video after the break.

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RC Car Gets F1-Style DRS Rear Wing

January 21, 2023 by 1 Comment

DRS, or the Drag Reduction System, has become a key part of Formula 1 in the past decade. [Engineering After Hours] decided to implement the same system on an RC car instead.

The DRS system was implemented in Formula 1 to increase passing in the series. By moving a flap in the rear wing of the race cars, drag could be reduced, allowing a car to attain a higher top speed on the straights. The racing series limited the activation of the DRS wing to only cars following closely behind another. This artificially enabled them to gain a speed boost over the car in front to aid passing.

[Engineering After Hours] wanted to see if a tiny wing on a small RC car could work the same way. It would fundamentally come down to whether moving a tiny wing element would appreciably change the car’s drag or not. Naturally, on such a small scale, attaining high speeds would be necessary to detect much difference. At lower speeds, the difference in drag would likely be too negligible to notice.

The RC-scale DRS system fundamentally does work. With DRS engaged, flattening out the rear wing elements noticably reduced downforce at the rear. With the DRS not engaged, though, the rear wing on the car was creating so much downforce that the car was squatting at the rear and occasionally flipping end over end. [Engineering After Hours] didn’t get any top speed measurements, but estimated that the wing could potentially increase top speed by up to 7 mph with the DRS enabled.

We’ve seen [Engineering After Hours] bring other fun motorsport tech to RC cars before, too, like this amazing fan car build.

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Cassette Player Cupholder Is A Useful But Risky Idea

January 20, 2023 by 36 Comments

The cup was invented in 1570 BC. Despite this, infuriatingly, the cupholder didn’t become common in the automotive world until the early 2000s. Cars built in the years PCH (pre-cupholder) typically also had tape decks. Noticing this relationship, [thephatmaster] designed this useful cassette-deck cupholder accessory.

The design is simple, consisting of a 3D printed ring with a tab that neatly slides into an automotive stereo’s cassette slot. The design does require that the tape deck be empty prior to inserting the cup holder. Given that few cassette players from that era still work, this isn’t much of a drawback. Of course, if you really do need tunes, it wouldn’t be too difficult to integrate a Bluetooth cassette adapter into the printed design.

[thephatmaster] uses the cupholder in a Mercedes W202, and has posted a special inclined version to suit this model. The creator also notes that using it on vehicles like the Mercedes W210 can be a risk. The cupholder typically places the beverage directly above the transmission lever, where any spills can damage switches or other important electronics. Also, the cupholder isn’t designed to work with vertical tape decks, though modification for this layout may be possible.

This build may look silly or pointless to some. But if you’ve ever tried to pull a U-turn in an old manual car while precariously cradling a steaming latte between your legs, you’ll clearly see the value here. It only has to save one pair of pants before it’s paid for itself.

We’ve seen some other creative cupholder hacks before too, like this nifty laptop holder. If you’ve whipped up your own nifty car hacks, send them into the tipsline.

A blue Mercedes SLS AMG sports car body with bicycle wheels. The gull wing is open to reveal the spartan interior and the hood is open to reveal an empty engine compartment since this is actually a bike.

SLS AMG Velomobile

January 9, 2023 by 14 Comments

Many gearheads dream of owning a supercar, but their exorbitant prices make them unattainable for all but the most affluent. [Andrzej Burek] decided to make his dreams come true by building his own supercar with a human-powered twist. [YouTube]

At first glance, [Burek]’s SLS AMG looks like the real thing. Pop the hood, and you’ll find this “car” is missing it’s V8 which has been replaced by a beefy speaker pumping out engine sounds from any car you choose. Both driver and passenger can provide propulsion for the sociable tandem, and the power is routed through a differential to the rear wheels. [Burek] decided to install the differential to make installing power assist motors simpler in future revisions of this quadracycle.

[Burek] said it’s taken him four years from buying the first component to the bike’s status in the video after the break. Other than the front and rear bumpers, he built the body himself out of fiberglass to learn how to work with the material. He welded the frame himself as well, and, in a testament to good measurements, the two parts fit together when united despite being built in separate locations. You can checkout more pictures on his Instagram.

If you want some more bike hacks, check out this Open Source Bike Computer or this Exercise Bike Game Controller.

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Mazda Patents Spinning Dorito To Extend EV Range

December 16, 2022 by 44 Comments

OK, so a Wankel engine doesn’t really use a Dorito as its cylinders, but it sure looks like one. The company has announced it will offer a range extender rotary engine for the MX-30 electric “crossover” vehicle, but [CarBuzz] dug into the patent papers to find out that it has some interesting twists.

The MX-30 is an EV with a relatively small 35.5 kWh battery. Like a hybrid vehicle, the car includes a small internal combustion engine that can charge the battery. It does not, however, directly drive the wheels at any time. The Wankel has several improvements, including a secondary port that allows more air into the combustion chamber when the engine has to produce high power. But there’s a problem…

The secondary port is great when you are pushing hard, but at low speed, it produces inefficiency. To combat that, Mazda includes a valve to seal off the second port when it doesn’t make sense to open it. But that’s not the strange part. The strange part is that the engine also has its own electric assist motor that runs off the main battery.  That’s right. The battery you are charging provides some energy to operate the electric assist motor to help the engine that is charging the battery. If that makes your head spin like the Wankel’s rotor, you aren’t alone.

The assist motor can assist or retard the output shaft during the intake stroke. This can optimize the intake to the combustion chamber. Of course, this will cause odd movement in the engine’s output, but since it doesn’t drive the car, who cares? The battery isn’t going to mind if the output isn’t smooth.

The Wankel shows up in a lot of odd places. We’ve seen Wankel air compressors. Despite detractors, there have been many improvements in the design over the years.

Building A Chain Drive Differential From Junkyard Parts

December 15, 2022 by 26 Comments

A differential is a very useful thing for a vehicle. It allows two driven wheels to rotate at different speeds, such as when going around a corner. [Workshop From Scratch] needed a chain driven differential, so set about building one from a salvaged automotive unit.

The differential itself was taken from a BMW E46 3-Series, specifically a 2.0-liter diesel model. The work began by removing the differential’s center gears from its big, hefty iron housing. Disassembly then ensued, with the spider gears removed from their carrier and the other components discarded. The differential gears themselves were installed instead in a new compact housing, fabricated with much welding and lathery. The housing was fitted with a large chain sprocket to deliver drive, in place of the original differential’s ring gear and pinion.

The video’s description states it would be an ideal differential for a go-kart, buggy, or other such small vehicle. Given the differential gears were originally built to handle a full-sized car, they should be more than capable of dealing with such applications.

If you’re a little unfamiliar with how differentials work, check out this primer from the early 20th century. It’s widely considered to be the best education on the topic. Video after the break.

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Build A Better Mousetrap… But It Better Be Better!

December 8, 2022 by 22 Comments

As creative problem solvers, we like to “think outside the box,” and we should strive for that. But what happens if your strange idea isn’t kept in check by cooler heads? There is a real danger — especially if you work alone — to falling so in love with your idea, that you lose sight of what it really means to be better.

Case in point. The self-parking car. Well, not the modern variant, which seems to work pretty well. But did you know that the self-parking car was invented in the 1930s and used an extra fifth wheel? Hard to imagine? See the video below. History tells us that the idea didn’t catch on.

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