[–] 5 points 5 days ago (3 children)

I know that feeling. Broke something in my reverse proxy and setting it back up again was painful. I know that certain things had needed special treatment, but how/what/where? Lost 🥲 Going to migrate to infrastructure as code for my documentation now

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  • [–] 1 point 5 days ago (1 child)

    Going down this rabbit hole right and wondering if you ended up with something? Already ended up here multiple times and really want to get this out of the way now. Someone suggested 'rollo' in another thread, but I don't really have access to those

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  • [–] 2 points 1 week ago* (last edited 1 week ago) (2 children)

    I agree very much with your suggestion. Just pick up some piece of wood and go for it. Nothing to loose, just pay attention and don't do anything with power tools where you don't feel save.

    Only on the sandpaper I would disagree - sure you can go to 1200, but spare yourself the time. 320 is more than enough in most cases.

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  • [–] 1 point 1 week ago* (1 child)

    IR transmitters

    Are you into that? I recently started fighting with my stupid ceiling fans and their IR remotes. Would like to get them into HomeAssistant, but are IR transmitters any good across rooms? Or would you have a transmitters right by the receiver and the transmitter speaks some other language for longer distance communication?

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  • [–] [S] 5 points 1 week ago* (1 child)

    I tried tape only, locating it above one and the same hole on my drill press. But the idea of tightly clamping on a piece of wood came afterwards as well. Will definitely try this - should I ever decide to make another one.

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  • [–] [S] 31 points 1 week ago (2 children)

    Close I would say. Never played pickleball so I can't point out the exact differences, but this is for 'Speckbrett'. There is no proper english term (baconboard would be the literal translation I guess lol) and it is very local to the Münsterland - an area in Germany. It is like a cheap tennis I would say - the weird rackets originated from cutting boards. And you play with a tennis ball, not a plastic ball.

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  • Plywood racket (feddit.org)
    submitted 1 week ago* (last edited 1 week ago) by to c/woodworking@lemmy.ca
     

    I needed a racket for some tennis like sport. Since the sport is kind of local to my area, there is only few offers for these rackets, and some have quite high waiting times. Since they are made from plywood anyway, I decided to make it myself.

    The melamin plywood I picked was a pain to work with, and I fiddled quite a bit with tape on the wood, drill speeds and everything, to avoid tearing the surface. I still did on the back, propably pushing too hard, so I scraped off the first layer. The clean black melamin would have looked better I think, but at some point I got so annoyed that I'm happy I was able to make it at least look decent.

    scraped backside

    [–] 12 points 1 month ago (3 children)

    What are your use cases for an app like this? Not trying to hate or anything - I just never used timeline and don't really get what it is doing for you?

    Looks very cool in any case!

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  • [–] [S] 1 point 1 month ago*

    I didn't even research into frames, but might if I like the feature on the TV.

    Just to be clear, I don't run it all day just to look at photos. Rather I have it show the photos on startup in the few minutes that I might take to select something to watch.

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  • submitted 1 month ago* (last edited 1 month ago) by to c/selfhosted@lemmy.world
     

    TL;DR DietPi has an easy to configure kiosk mode to boot up opening a website. E.g. your gallery displayed with ImmichFrame

    The photos

    Part of my post vacation workflow involves collecting all photos taken, sorting out the 90% duplicates and blurry ones, and slapping the remaining into an album. There they can sit until some unlucky person asks me about my last journey, or I get an urge to look at them again (about once every three years).

    Since using Immich I get these flashbacks a little more often, since it has this memory feature that shows photos from x years ago (folders don't have that. Yeah I used folders before). This still involves opening the app on my phone though, which I'd like to use less in the first place. If only there I had a big screen somewhere in my home that could display images at a decent resolution...

    The frame

    There is digital frames for that, but I don't want to make room for one. Maybe later. What I realized is: My TV displays this one (pseudo) artsy drawing whenever I turn it on. Instead of seeing this same boring image 5-10min every day: Why not enjoy my photos?

    There might be a TV app for that, but I don't want to be opening/installing apps on the TV - I need my photos to show in the 'default' mode (which might be possible with an app, but I didn't bother to check). Instead I grabbed an old RPi3 and installed Raspbian RaspberryPiOS (it has been a while...) and ImmichFrame. A promising looking app that is meant to take my Immich albums and display them. Everything worked super quick, but opening the browser to display the ImmichFrame page hosted in Docker. While messing with a script to open the browser on boot, I noticed that everything felt a little (a lot) laggy. (In hindsight I was probably overheating my little PI due to missing cooling. Fixed this later as well)

    The diet

    Looking at lightweight OS for the Pi, I discovered DietPi and gave it a quick install. It is very convenient to configure via the console, and while messing around there I stumbled across something-something kiosk mode. That's exactly what I needed! Lucky me didn't know about such things, but it makes sense I guess. Just configure a URL and it will display that page on every boot. Currently ImmichFrame is hosted on the PI as well, so I added a little wait loop into the startup of the kiosk mode, but that's all. Performance is ok right now, but if it continues to lag, I'll just host ImmichFrame on my server.

    The Pi gets plugged into the TV and is running all the time, since I could not think of a smarter way. Now I have a neat solution that is fully under my control.

     

    Growing up we always had a garden. This meant fresh veggies and tasty fruit throughout most of the year. And even though I never had a cliché hatred for anything green, I never really appreciated this either. It was just normal.

    Moving into a city really changed that, and spoiled me realized that not everyone has a garden. Nor parents that spend loads of their free time dealing with it. So while I’m grateful in retrospect at least, that still does not bring back that tasty salad from back in the days. What does not help either, is that I’m already annoyed by the repetitive watering chores for the few plants that actually do live on our balcony at the moment.

    In comes TheStockPot. A youtuber that, among other cool stuff, build a smart greenhouse. While I’m sure he is not the first one with this idea (in fact the farmBot has been in my head for years), it’s his video that sparked my motivation. So if you like watching videos, this is where you should leave the post and just watch the video instead. All the credit goes to him and all I have to add will be some tinkering with electronics from a beginners POV. And some woodworking.

    The idea

    If you are still here, the idea is pretty straight forward: Take (or build) a greenhouse, lob some sensors in there, add a water pump, connect everything to Home Assistant and get an infinite supply of vegetables without spending time watering or going to the supermarket. So like any sane person, I ignored all the financial and time consumely implications and set out to build something alike.

    The hardware

    The system is based on an esp32 board with relays. A microcontroller with wifi that nicely integrates into Home Assistant.

    Relay Board

    The relays allow supplying any odd electrical device with up to 230V. The "original" uses them to power heating mats to better manage the temperature inside the greenhouse (which I don't). I used it because I didn’t think and just did what the video did. Actually I currently only use it to power one 12V pump. Speaking about 12V: I picked a 12V membrane pump since the board also takes 12V. This way I only need to run one power cable and there is no need to mess with high voltage. For sensors I used a DHT11 (air temp and humidity) and multiple DS18B20 (soil temp). Since I don't run active heating (or cooling) atm, these are not really required. They were wired in because they are cheap and I like data (and heating might get added, who knows). Lastly there is a simple float switch to turn off the pump when my water container runs low (I don't run tap water).

    Float switch and intake unit

    Everything is stuck together with some resistors on a prototyping board, which I did for the first time. It was super doable for a solder beginner, and I learned quite a bit! Sticking multiple sensors together and supplying things with power made me think about what's going on and how to get everything connected with as little mess as possible. Way more interesting (and challenging) than following some laid out tutorial.

    Don't solder everything to the board but make it disconnectable would be my own thought to share, for everything else there is more qualified people out there.

    The software

    ESPHome is super cool! If you run Home Assistant and want to integrate some custom devices, definitely give it a look. It’s a convenient and easy way to program your hardware. One maybe helpful note: Starting out I ran the ESPHome Device Builder on my Home Assistant instance (= a Raspberry PI 3). Compiling was really hard on that little guy and took forever. I switched to running a container on my local machine which made the whole process a lot quicker. Also make sure you have access to a USB to TTL adapter to program your board. Regarding the code I’ll happily point you to TheStockPot blog, which I used as a base for my own greenhouse. Biggest change I made was to remove the heating and add a float switch that prevents misting when the water is low.

    In addition to that, I added a temperature sensitive automation in Home Assistant. Every time the temperature falls below 3 degrees C it disables the pump. This way I hope to prevent it running when things start to freeze.

    The woodware

    Building the frame from wood has the obvious downside that it will probably likely rot and the upside that it was free. Most pieces are planed roofing timber that I notched on the table saw. Notches for the windows were also cut on the table saw. Other than a little miscalculation in the width, everything went smoothly.

    frame layout

    Throw in some preowned hardware, and this was the cheapest part of the build. One of those cheap, plastic skinned houses would likely do just as well (likely better due to better isolation), but where is the fun in that?

    The résumé

    Like (almost) always: It was a fun journey! Like also almost always: It was pricier than expected. Other than the controller and sensors listed above, I spend quite some money on other electronic related items (enclosure, prototyping board, wires, standoffs and other tiny bits). So from a financial standpoint, I don't think it'll pay for itself any time soon (in particular since I already have a version 2 in mind).

    misters in action

    From a non financial standpoint it was (and is) a super enjoyable project! Starting with the first click of the relays, to wiring with a prototyping board, to checking my PlantStats™ every day, to watching my little plants grow. There was tons to learn and there is tons to improve! Some in this version some in the next. I still have to work on the watering schedule and the perfect placement for my misters. Also I might need to seal my housing a little better.

    submitted 4 months ago* (last edited 4 months ago) by to c/opensource@lemmy.ml
     

    For longer touring and casual sport cycling I want to finally get my hands on a bike computer. Have used my phone so far, but I don't like

    • battery life
    • water situation when it's rainy
    • arguably not too good for the camera stabilizer

    My requirements are not too high I would say, but I would like

    • connectivity to some peripherals (ANT+ I guess)
    • ability to add GPX files and also extract them
    • not buy myself into some cloud (or otherwise fenced) solution

    What it boils down to: What would be the least restrictive brand out there?

    I am aware of https://github.com/hishizuka/pizero_bikecomputer but currently I don’t see myself tinkering that much – since I do longer tours I need some kind of decent case, a way to take it off and be a little tough.

    (Sorry if this is not he perfect place, I could not think of another community that would fit well)

     

    Unlike most people these days (at least that's what it seems like) I don't own a 3D printer. But a soldering iron is a little like a 3D printer, I assume: as soon as you have it, you find all kinds of uses for it. And while the project I got it for has long been abandoned, I find myself using it quite a bit. My latest addition were a few helping hands inspired by Matthias Wandel, which beats "fixturing" with pliers and random heavy objects. Which led to even more soldering. And while all soldering guides (of the 1 I actually watched) tell you to take care of ventilation, sitting in your freezing cold room, windows open, and holding your breath makes you really think about all those funny-looking fumes.

    Disclaimer

    Don't get me wrong: I love inhaling toxic fumes like the next person that has bought spray paint to "revive" their plain white IKEA shelf. Jokes aside, work safety is important! The inspiration for this fume extractor was taken from other DIY online posts and I have no way of verifying its effectiveness in cleaning the air. I will always crack a window in addition to using this extractor.

    Design Considerations

    In particular industrial extractors come with some kind of snout - a piece of flexible tube to position the air intake right above the soldering job. This seems very smart, and I almost went to shop for more parts to join the 12V PC fan and the activated carbon filter already sitting on my desk. However, I did a bench test with the setup at hand and decided to not let scope creep get me this time. The fan I chose really moved some air, and it felt like I could arrange my little setup in a way that does not compromise on extraction action too much. The other place where I considered LocLine was for mounting the fan to its stand, which I skipped for the same reason. The last thought that had the potential to complicate things was the wiring. My soldering iron runs on USB-C - I don't have a full-blown soldering station (yet). I have seen a solution online where all power needs kind of merged at one place, which I really liked. Unlike in the post however, I decided against putting all the controls by the fan. The reason being that I decided to put my fan on a stand and add some pivoting capabilities. Messing with switches and cables on that likely top-heavy contraption did not seem like a good idea. So cables will go on the stand, where they are easy to reach and replace (should I ever get to actually installing them).

    Build

    As stated above, I don't own a 3D printer (yet). So instead of printing this straight forward piece, I spend the better part of my weekend sawing, screwing, glueing and painting this straight forward piece. I made the dimensions up on the fly and cut everything down with my track saw. The circles were cut with a jig for the router and everything went together with glue and some screws.

    (Finished fan enclosure

    After I had everything together, I decided that this thing deserved a nice finish. After all, it will sit on my desk right in sight. Luckily I had used the cheapest plywood I could find, so I got to do loads of filling and sanding. After enjoying that for a while, I decided it did not deserve that nice of a finish. Even after multiple coats of filler, sanding, and primer, I can still see some wood texture and make out where the screws went (when looking closely at least). Also, I had decided that adding holes for threading inserts AFTER finishing would be a smart idea. It was not - the finish was messed up in the process.

    Filling in progress

    The filter can be replaced through a little opening in the top. Even though it looks a little messy, at least I don't have to get out a screwdriver to do this. If you own a lathe or have to go to the hardware store anyway, I think the top could be fully closed, and rather have some thumbscrews for opening the lid. In between the fan and the filter sheet I added some 5mm wooden strips that were glued to the fan. This way nothing can rub against the blades of the fan.

    For the stand, I just screwed a few thicker pieces of plywood together and called it done. This will later hold a switch and some wiring (probably maybe).

    Extraction Action

    (yes, I increased the length of the legs in the meanwhile, hence the different look in the thumbnail)

    Resume

    After having used it a little now I can say: It was absolutely worth it! Soldering indoors feels much more bearable and I would even call it an absolute must-have from now on!

    Like with every project of course, there still is room for improvement:

    • I made everything up on the go. That worked out, but it's not fancy-looking or anything. My helping hands are neither, so that's fine I guess
    • Put the pivot point lower on the fan to get some more flexibility in positioning
    • Make the base from something denser and slim down the legs to cut down the footprint a little
    • Add a shroud
    • Elongated holes in the stand would be nice for further adjusting flexibility
    • When installing the wiring, I will also try to add a light on top of the fan.
    submitted 8 months ago* (last edited 8 months ago) by to c/diy@beehaw.org
     

    Or: How I made the single most flammable object in my flat.

    Harry had never even imagined such a strange and splendid place. It was lit by thousands and thousands of candles that were floating in midair over four long tables, where the rest of the students were sitting.

    And while I would love to say that it was this line that inspired me, it was rather a friend of mine that had those 20$ plastic candles hanging from strings in her hallway. Waving a plastic wand around they not only turned on, but also left quite the impression on me. However, the more keen eyed might have already noticed: There are no candles on my photos. There's no wand either. This is not even about floating candles and I'm just about done with them. Now while I really liked the looks, I didn't like the thought of changing batteries every week (I never checked the runtime of those plastic candles you find everywhere, but I doubt it's anywhere near acceptable for me). Adding permanent wiring came to my mind, but this would require hiding cables and a transformer somewhere. Not that easy with the average ceiling, at least if you live in a rented flat and consider moving within the next 15 years. Luckily J.K. Rowling also came up with this whole indoor cloud thing, so I ended up with a build idea after all.

    Now that you know how this idea came about, let me ramble about the build a little. Not that I think I'm the most qualified person to do this - you will be able to find plenty of images online where people did the same thing, arguably lots nicer than my own build. But no one tells you that you should not be doing this because it's annoying and sticky and fiber gets everywhere. Also it's not unlikely to catch fire and burn down my whole apartment with it. But starting from the start: I grabbed some cheap 20mm thick foam board, attached two wooden cross members to it and into those some hooks. This way I can hang the whole sheet to the ceiling and also got space for the cable bits. While still being cumbersome to hang, it allows for an undisturbed underside (where the cloud part is). And even more important: The cloud can be assembled on the living room floor (or any other floor you would like to cover in glue and fiberfill). Next were the LEDs, where I grabbed 8m of 60LEDs/m strip. With a fitting transformers and a ZigBee controller everything lights up and integrates into Home Assistant. Playing a little with the look I decided on a fairly dense layout, leaving only around 5cm between the rows of LEDs. The fiberfill does a good job of covering up whichever bad job you did laying out the LEDs and no one will be able to see that you bend the strips around the corners instead of doing a proper wiring job. Speaking of the fiberfill: You don't need much of it. If I had to guess, 500g would be plenty for my 120*60cm panel. I don't have an exact number here, but the reason is not that I seem to have no perception of how much 5kg of fiberfill are. So I totally don't have a human sized box of fiberfill sitting in my apartment that barely lost any weight. And even though it's not much weight you need for the cloud, it sure seems like a lot when it frees itself from the double sided tape and comes tumbling down. After being pissed at the tape and myself for being lazy, I did it 'right'. Hot glue and spray glue did a good job at fixing the fiberfill to the foam board, my hands and the floor. No more cloud fall so far.

    All jokes aside: I tried to sneak a few actual numbers and useful information into my text, and yes it was annoying to build. On the other hand it's low effort in both tool requirements and cost. If you have a way of getting outside for the glue up, I'm certain that's a good idea. At least if you use spray glue. Also while the fiberfill did a great job at covering up the LEDs and making it look fluffy, it barely covered up the contour of my very rectangular board. I thought it would do more here, but it is what it is now. And regarding the fire hazard: Enclosing the strips in aluminium channels is certainly a good idea!

    More complete view

    The whole looks is not for everyone and I'm fully prepared to take it down in a year or two because it turned into a filthy rain cloud. But until then it sure does give off some nice light and makes for an interesting piece to look at.

     

    This is not a post about a build of some kind, but more of a research/question. So no build photos right now, but if you have some input I would be happy to read it :)

    After having to do some flying the past days and my soft/fabric suitcase breaking apart I looked into getting a replacement. What I need is a large suitcase for checked luggage. Not some crazy odd or large shape, but a decent suitcase for (multi) week traveling. I love the old Aluminium rimowa cases, but they are super pricey and I also heard quality is not what it used to be. So I thought: Maybe I can build an Aluminium case myself? Surprisingly I can't find too much online about selfmade suitcases. Does anyone have experience/resources regarding this? Are there regulations (other than size) I would have to follow?

    Zarges (alu crates) is quite the name around here, and my first naive thought was: Rivet some wheels and a handle to that thing and you have a nice case. Of course I would want to go a little further here, but do you think that would be somewhat feasible?

    Thanks for reading and I am happy for any feedback :)

     

    Who doesn't love opening a loot crate? Not the gambling stuff (well it's still kind of gambling), but the ones in game. The ones that give shitty loot and guns you don't know how to play. The ones that make you end up with a bullet in your head 50% of the time because you drive into the middle of nowhere to get them.

    Ok this will not be about stupid PUBG references, but thoughts and images of the process of making a "PUBG loot crate" for a friend of mine. For everyone unaware, it looks something like this:

    in game crate

    Goal:

    • build a small loot crate that vaguely resembles a PUBG loot crate
    • make it from wood (3D printing would have been an option here, but I just don't like the look and feel too much for such a project)
    • improve my wood finishing & painting skills

    Not goals:

    • make an exact copy of the in game loot crate from PUBG
    • spend tons of time and money on it
    • get 50 new tools

    The box

    While making a wooden box is indeed a skill to learn, having it heavily painted and modified made me not want to spend too much time on it. So I just bought one and sanded it smooth (not enough).

    bought box

    To add some depth to it, I went to add a bottom and some ridges to resemble the corrugated panels of metal containers. The ridges were cut by hand and everything was sanded (almost enough) before glue up. I used normal wood glue and clamps, no nails or screws. For alignment I had done some marking with pencil and it ended up fine. For a more precise project, I would have made small spacers and nailed everything in place with a nail gun (which I don't have). Getting rid of the glue with a wet cloth was crucial here, because hand sanding all the inside edges would not have been fun. Some wood filler was used to even out small imperfections, but I should have used even more here. In the finished product I can see where I did a good job and where I got lazy.

    ridges

    Each vertical piece was glued on as one, just because that seemed easier. Of course I had to split the box again, which was easy enough with a hand saw.

    split box

    The paint

    After the glue up, paint was up next. 3 coats of primer went on with sanding in between. 180 and later on 240. It still showed some wood pattern at this point, but I would not know how to improve this. Not buy cheap ass primer? Sand more? Even more coats?

    After that, I sprayed it with red paint and also lightly sanded with a 320 grid sanding sponge. This ended up looking just about how I wanted, but could still have been a little smoother. Painting is hard. Also I need to build some painting triangles, because it got stuck to the underground twice.

    painted red box

    The finish

    Last paint related thing was the rough look. With nothing else on hand, I dabbed on acrylic paint. It did not seem to stick in the beginning so I went all in. To an extend that I thought I had ruined the piece when it was all dry. Looked like a cheap ass camo clothing pattern designed by a 3yo (or something even worse).

    camo look

    First I tried to carefully remove only the top coat of acrylic, but this quickly hurt the lower coats until even the primer showed. So I just went to town with all my sanding paper and even a paint scraper. Took way more time than I wanted, but at least it turned out ok. A sanding sponge came in clutch here for reaching all the crevices. Definitely a worthwhile 'tool' to have. This is the part where I would be interested in other approaches to achieve this look - something I have to look into.

    used look

    The extra bits

    For the straps I just ordered some 10mm wide nylon band. Could have payed more attention here: The straps are not simply cut and go, but I had to get out the sewing machine to attach the plastic bits.

    straps

    Also simply no one seems to own one of these blue IKEA bags anymore, so I had to cut up some old apron for the blue top. Not exactly what I was looking for, but got it close enough.

    The resume

    Fun project, that of course took longer than expected. My learning with the paint is once again: Take your time! I think I would have needed to spend more time on almost every step to get that 'perfect' finish. But for the first time it felt achievable with my equipment on hand. That's encouraging! Since, on this project, everything was roughed up anyway, it did not feel like a failure. The rest was pretty straight forward and it was a really enjoyable project with minimal space and tool requirements.

    finished box

     

    TL;DR: This is a ramble about my old and new keyboards, with some finger pain along the way.

    • Hotswap has it's drawbacks
    • QMK is nice
    • I like macro keys

    Due to my job and love for gaming, I spend quite a bit of time in front of a keyboard. With that in mind (and also some enabling colleagues) I went on a big long search for the perfect keyboard. Quickly I became interested in split designs and finally pulled the trigger on a Mistel Barocco MD770. It's now 1.5 years later, and this text was not typed on the Mistel.

    The old

    The Mistel Barocco MD770 is a super nice keyboard. I like the clean look, the split form factor and the fact that I can 'merge' it into a 'normal' keyboard. This saves me from messing with the whole keymap when gaming. What I had to fiddle with however, was the keybinds while not gaming. There is no GUI for that and you have to do it by combinations of key presses. It worked, but I had to check the manual every time I wanted to change something. Also the bluetooth connection often took some time (no issues when wired) to get going. So it had it's minor drawbacks, but not enough for me to go out searching again. After over a year with the board however, an issue pressing enough came up.

    Mistel Barocco

    The issue

    Being a gamer all my life, I never really had issues with hand or finger pain. But getting older and/or really diving into FPS about half a year ago messed with that. After longer gaming sessions I started to notice pain in the fingers of my left hand. Since I also do climbing, it took quite some time for me to figure out, that in fact the gaming is the issue. It seems I press WASD like a mad man when running around. Press less hard then - duhhh! I tried, but the MX Brown switches just didn't give the feedback my fingers needed.

    I like climbing, I like gaming and I wanted this fixed quickly. My best idea, apart from tying to press less hard, was to find switches with a clearer feedback. This is when I discovered, that the Mistel sadly does NOT have a hotswap PCB. Which leads us to chapter three.

    The new

    With virtually endless options for keyboards and some money to throw at the problem, I was not quite ready to desolder my whole keyboard. So I went out there with my requirements figured out:

    • split layout that can mesh together (for the reason above)
    • hotswap (because that's what made me end up here)
    • staggered is fine
    • QMK support
    • (macro keys)

    The rest was mostly a gut decision - I found the Keychron Q11, liked the mostly clean look and the macro keys and just went with it.

    Keychron Q11

    With it I ordered some Cherry MX ERGO CLEAR, some cheapish keycaps that at least support this split layout and some O-rings. Most important answer first: Yes it helped with the finger pain! The actuation point is way more recognizable and the O-rings make the bottom out a lot less hard. I love the switches and also the sound is quite nice. The dedicated macro keys including a GUI to set them all up are also a major improvement in my books. I use them for media management and some undo-redo action which is super convenient. The keyboard itself is also quite beefy with its aluminuim body - not a super big deal but it feels nice. Last thing I want to talk about are the hotswap sockets: You just push in your switches and are ready to go - sounds super easy. And it is. Unless you don't have any feeling in your fingers (duhhh again) and just smash them in. I broke some sockets. Nothing that could not be fixed with some solder, but I was not even aware that this is an option. My fault but still something to watch out for at least.

    submitted 1 year ago* (last edited 1 year ago) by to c/diy@beehaw.org
     

    This year I did my first bike packing trip. For starting out I had rented some equipment, but with the goal of doing more trips in the future, getting some bags of my own was clearly on the list. With the idea of using panniers for my main storage, I wanted to add some fork bags to balance out the weight a little. Also they are the least obstructive (other than frame bag maybe) from my POV. Somewhat enjoying DIY, the idea of designing the cages myself grew on me.

    What this is

    Some insights and thoughts on the process of designing and making some aluminium cargo cages for a bike.

    What this isn't

    A guide on how to design and make aluminium cargo cages for a bike. I have no professional training on anything I did here. This is my first time doing something like this.

    Designing

    Sketch

    After making some sketches on paper, I quickly jumped into 3D modelling on the PC.

    The software

    The software I choose was OpenSCAD. Reasoning was that I like open source software and I don't know any CAD software anyway. With it being a non-interactive tool, I hoped to somewhat make use of my coding knowledge/background. You write a script and the tool compiles it into a 3D model.

    This however, did not work out very well. Going into it without much of a plan, I ended up with a very confusing file with loads of duplicate code and lots of guessing when trying to figure out dimensions. This was not the fault of the tool, but only my own. Not saying I'll never go back to it, but for the next job I will try some more interactive tooling. Some more structure and thought out process would benefit any tool however, so that's a learning I'll take with me.

    The looks

    Hard requirements were the screw positions for mounting to the fork and space for some straps where the bag is attached. In the middle of designing I noticed, that I might want some material running from the screw attachment points across the whole width of the piece (this might not have been required since the 3mm aluminium I used was plenty strong).

    The whole design evolved around these requirements and some hexagons I wanted to add. Everything was kept symmetric and I tried to pick up the angles from the hexagons in the other angled pieces.

    For sizing, I tested my dimensions on some cardboard cutouts and went with what felt right.

    Finished cage design

    The issues

    • The lower part was meant to be bent around and then welded at the seams. However I failed to provide additional material for the bending, therefor it was cut of and completely welded in the final product.
    • The lower part is too wide. Instead of taking a second to think about it, I just kept the lower piece wide with the idea of grinding of the excess. I should have made the diagonal piece of the notch the same length as the vertical line it will get welded to.
    • The straps of my chosen bags do not line up perfectly with the cutouts on the cage. There is enough space to make it work and not look super off, but it would be smarter to get the 'target bag' first.

    Also I think it turned out a little like any cage you can buy in a shop. Wish I had made it a little more unique, maybe carry the hexagon idea along the edges...

    Fabricating

    Having access to at least some of the tools required for fabrication made the project seem somewhat reasonable in the first place. I would not know how to go about this, if you don't have a welder (other than designing a part that does not require welding).

    Laser cutting

    The whole idea heavily evolved around the idea of using a laser to cut my model from some aluminium sheet. However the laser I planned to use was not available anymore by the time the design was finished. No big deal I thought, there are ordering services for just about anything online. Which there are. But many of them ask a heavy fee for low part counts. To a level that would shut down the whole idea. It took quite some searching until I found someone willing to do the job for a feasible price. Had I not found a laser, filling and cutting with a saw would have been my last resort. Luckily it didn't come to that.

    Other than the design issues mentioned above, it turned out just like I wanted!

    Welding

    You should find someone else to tell you about TIG welding. On the photo you can see the lower base that turned out too wide and never got ground off. Also the lower base that was cut off instead of bend due to missing clearance.

    Welded cage

    Painting

    3 base coats, 3 top coats of matt black. Some deburing beforehand would have helped the final look as well. I always underestimate how much all these details show up after painting.

    Finished cage

    Bags

    For bags, I decided on Cube ACID PACK PRO 3 (which are 3 liter bags). Even though I bought these, this was not the super easy part. Going into this project my thought was that it will be super easy to find fitting bags. But I had to do quite some digging to find something I liked. 3 liters per site are plenty for my setup, since I just want to spread some weight forward. I have seen these cages used with 5 liter bags, which worked fine as well. The straps do not line up perfectly with the cage, but there is enough wiggle room to make it work.

    Cage with bag

    Final thoughts

    It was a fun project and I will hopefully get to enjoy these cages for a long time. Without having done most of the things required to tackle this project, it took me quite some time to do. But I learned a lot and will surely go into my next CAD/metal/fabrication project with more of a plan!

    I hope someone can get something out of my post. This checklist should help if you consider doing a similar project (maybe even any DIY project at all)

    Don't do this if you

    • want to save money
    • need some cages quickly

    Do this if you

    • enjoy making stuff!
     

    Recently I quit Strava and started using OsmAnd to do my routing and also recording of bike trips.

    I can store and view the tracks fine, but the interface really is just for viewing single tracks. I would like to organize my recorded trips a little better, in a fashion that e.g. Strava allows:

    • add some meta information
    • compare tracks and all the related info
    • extract some further data from the tracks and compare them (something like "your fastest 2k")

    Is something like this out there? (I did not deep dive into GPX itself, maybe I am looking for something that is not even in the data)

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