greatwazoo42
Master Member
Good gravy. This thing is turning into one of the most beautiful complex 3D puzzles I've ever seen. Amazing work!
Re-imagining the 11th Dr. Sonic screwdriver..
- Thread starter tailgunner30uk
- Start date
tailgunner30uk
Active Member
Thanks for that, however if you think this is complex, you definitely do not want to see what is going through my head W.R.T the next one. Even more moving parts, even smaller, I'll probably have men in white coats queueing at the front door and a padded cell waiting for me. I will have psychiatrists dreaming up impressively long Latin names to describe this affliction. It already keeps me up at night...
greatwazoo42
Master Member
Either that or you'll finally have made a sonic that can not only work on wood but also make a meeeeeeeeeeean cup of Joe.
NakedMoleRat
Legendary Member
Well, since you won't be needing this one....and our fan series will film in February..... :thumbsup
Just found this. What a great sonic. I've always love brass & silver look, it adds a bit of class, used to great effect on this piece 
Would even look good without the claws as the dish gives it a little something extra. The gubbins inside the tube is also a neat touch, could easily see them sparking up when the sonic is activated. A very classy bit of work.
Would even look good without the claws as the dish gives it a little something extra. The gubbins inside the tube is also a neat touch, could easily see them sparking up when the sonic is activated. A very classy bit of work.
tailgunner30uk
Active Member
Hi all, thanks for the comments.
Hi N.M.R. I just wandered over to your thread, the N.M.P.G. (Ninja Meerkat Patrol Group) are in a state of shock after seeing what you did, and have now redoubled patrols around the sonic
Thanks for your comment Muldwych, It has been fun making it, The dish came about after drawing and redrawing the sonic head, to find something I liked. There is still a ton of work to do, but I have now ordered the batteries and chargers so I will be making the battery compartment then wiring up the switches, I keep saying that but never get round to it, ah well I'll get there.
The next Sonic design is underway, sketches are being drawn and discarded, ideas floated and sunk. The parabolic dish will be back, and I am working on a fold away Halo for it. Mechanically possible, but takes my mediocre engineering skills to a new and scary place.
A new, full update at the end of the weekend, pictures and all manner of other goodies.
Have to do something for the 5000th view.
Hi N.M.R. I just wandered over to your thread, the N.M.P.G. (Ninja Meerkat Patrol Group) are in a state of shock after seeing what you did, and have now redoubled patrols around the sonic
Thanks for your comment Muldwych, It has been fun making it, The dish came about after drawing and redrawing the sonic head, to find something I liked. There is still a ton of work to do, but I have now ordered the batteries and chargers so I will be making the battery compartment then wiring up the switches, I keep saying that but never get round to it, ah well I'll get there.
The next Sonic design is underway, sketches are being drawn and discarded, ideas floated and sunk. The parabolic dish will be back, and I am working on a fold away Halo for it. Mechanically possible, but takes my mediocre engineering skills to a new and scary place.
A new, full update at the end of the weekend, pictures and all manner of other goodies.
Have to do something for the 5000th view.
Last edited:
ponchopanda
Active Member
I've been watching this thread since it was announced that it was the winner, good luck tailgunner.
sonicprops
Active Member
looks amazing cant wait for updates
the DOCTOR
Sr Member
Excellent build, with a wry and amusing write-up: More Please!
truly re-imagining a sonic!
tailgunner30uk
Active Member
Hi, all.
Sorry I have been away for so long. Things got a little heavy towards the end of last year, and the sonic had to be put on the back burner for a while. Anyway, just a quick note to let you all know, normal service is about to be resumed.
So a short update and pics to follow this weekend.
Where am I, oh yes, all of the main parts are now made, and I have started work on the electronics that somehow I have to fit inside the screwdriver. As I started the wiring I realised that 'TAC' switches only come as single pole, which rather threw my plans into a hoop. After cursing for a while and generally kicking inanimate objects whilst grumbling about the inadequacies of the electronics industry, |I came up with not one but two alternate plans.
Plan A. Order some 6*3 mm tactile switches and mount them in pairs with a button to activate each pair individually, simulating two double pole switches.
Plan B. I ordered a surface mount H-Bridge to control the motor using the original switches. Machined a small round PCB to fit into the handle and am currently in the process of finishing the wiring, and trying to figure out HOW THE HELL am I going to install all of this spaghetti inside the sonic.
I went with plan B first, well I never claimed I was sane.
See you soon.
Sorry I have been away for so long. Things got a little heavy towards the end of last year, and the sonic had to be put on the back burner for a while. Anyway, just a quick note to let you all know, normal service is about to be resumed.
So a short update and pics to follow this weekend.
Where am I, oh yes, all of the main parts are now made, and I have started work on the electronics that somehow I have to fit inside the screwdriver. As I started the wiring I realised that 'TAC' switches only come as single pole, which rather threw my plans into a hoop. After cursing for a while and generally kicking inanimate objects whilst grumbling about the inadequacies of the electronics industry, |I came up with not one but two alternate plans.
Plan A. Order some 6*3 mm tactile switches and mount them in pairs with a button to activate each pair individually, simulating two double pole switches.
Plan B. I ordered a surface mount H-Bridge to control the motor using the original switches. Machined a small round PCB to fit into the handle and am currently in the process of finishing the wiring, and trying to figure out HOW THE HELL am I going to install all of this spaghetti inside the sonic.
I went with plan B first, well I never claimed I was sane.
See you soon.
Last edited:
tailgunner30uk
Active Member
@Ponchopanda.
What did I win?
Damn I HAVE been away too long! :facepalm
What did I win?
Damn I HAVE been away too long! :facepalm
tailgunner30uk
Active Member
Good evening, and welcome to the next installment of the ever lengthening saga that is THE SONIC'S REVENGE...
It has been a while hasn't it., strangely enough, it seems I haven't been missed. I won't take it personally though! (Turns away from the screen muttering under his breath.)
So anyway, how have you all been, good Holiday season, lots of interesting presents eh. Gooood...
So shall we begin. <ED. I think that's a good idea.>
Over the last few weeks, not a lot has been done, cold, short nights, other things, have got in the way but small parts have been made, some modifications to the sonic have been completed and there is a light at the end of the tunnel. There have been three main parts of the project that I have been trying to get done. Finishing the gearbox, installing the wiring and completing the battery holder.
I'll start with the wiring, although this isn't finished yet.
<ED. How suprising.> Listen you, if you don't stop interrupting we'll have to settle this like gentlemen. <ED. Bwaa Haa Haaa.>
Damn. Anyway, I have wired up the switches to and soldered them onto the custom pcb made for the H-Bridge and the resistor for the LED. The LED is a high brightness white LED which has been modified by cutting off the dome and polishing the flat face so that it will fit below the blue acrylic shaft. I blew up the first one, a 9v battery and no resistor, it burned brightly but not for long.
The resistor is 110 ohm, enough to reduce the current through the LED. As I said I made a pcb, first time ever! as the H-Bridge chip came as a surface mount package 4mm by 8mm approximately. This pcb seats into a circular recess in the brass section of the handle just above the battery compartment. If the H-Bridge doesn't work as I hope, I have ordered some 3*6mm Tactile switches to replace the 6*6 switches for the motor, and designed a pcb for these instead. That will be machined on the mill in the next couple of days.
Ah yes, the mill. Recently I have been getting a terrible amount of backlash, particularly in the Y-axis, whilst this could be compensated for, I decided to bite the bullet and replace the X and Y axis nuts for adjustable nuts. (Now then, now THEN... titter ye not.) This involved stripping, (No. Listen, I've told you about this before... settle down.) down the mill, replacing the nuts
and reassembling, then adjusting the nuts and ways to reduce the backlash to manageable levels.
And now on to the battery compartment. A plastic sleeve and cap has beem machined to contain the batteries, which are two LI.Ion rechargeable batteries. Unfortunately these cannot be recharged in series. Therefore the handle has been modified with a bayonet fitting to allow easy removal of the batteries for replacement and recharging...
And finally for this episode- <ED. and about time too, oooof. thud.>
I warned him, I really did. -The gearbox. I have finally assembled this part, and it seems to work, although it seems to need more power than I hoped, with any luck that will improve with running in. The pinion gear has been soldered onto the output shaft of the motor as have the two gears for the two shafts that move the extending tube. It is a little rough but it works.
So what is left. Well the wiring needs to be finished. The final parts for the battery compartment need to be made and installed. All parts need to be polished and reassembled into their various assemblies, and then... I have to work out how to put it all together.
Are you ready for some pictures. and a link to a video...
Well first, the ongoing saga, Hitch-hiking around the Galaxy on 20 Altairian dollars a day.
... I stopped off on Earth a few days ago, and met an interesting chap, Wonko the Sane, he called himself. He told me about some travellers he met recently, Fenchurch and Arthur. We've met I said, small world was his riposte. As I left I helped myself to a couple of toothpicks and returned to the world of the insane.
the video.
ms sonic gearbox - YouTube
And the pics. (now where did that Editor go...)
It has been a while hasn't it., strangely enough, it seems I haven't been missed. I won't take it personally though! (Turns away from the screen muttering under his breath.)
So anyway, how have you all been, good Holiday season, lots of interesting presents eh. Gooood...
So shall we begin. <ED. I think that's a good idea.>
Over the last few weeks, not a lot has been done, cold, short nights, other things, have got in the way but small parts have been made, some modifications to the sonic have been completed and there is a light at the end of the tunnel. There have been three main parts of the project that I have been trying to get done. Finishing the gearbox, installing the wiring and completing the battery holder.
I'll start with the wiring, although this isn't finished yet.
<ED. How suprising.> Listen you, if you don't stop interrupting we'll have to settle this like gentlemen. <ED. Bwaa Haa Haaa.>
Damn. Anyway, I have wired up the switches to and soldered them onto the custom pcb made for the H-Bridge and the resistor for the LED. The LED is a high brightness white LED which has been modified by cutting off the dome and polishing the flat face so that it will fit below the blue acrylic shaft. I blew up the first one, a 9v battery and no resistor, it burned brightly but not for long.
The resistor is 110 ohm, enough to reduce the current through the LED. As I said I made a pcb, first time ever! as the H-Bridge chip came as a surface mount package 4mm by 8mm approximately. This pcb seats into a circular recess in the brass section of the handle just above the battery compartment. If the H-Bridge doesn't work as I hope, I have ordered some 3*6mm Tactile switches to replace the 6*6 switches for the motor, and designed a pcb for these instead. That will be machined on the mill in the next couple of days.
Ah yes, the mill. Recently I have been getting a terrible amount of backlash, particularly in the Y-axis, whilst this could be compensated for, I decided to bite the bullet and replace the X and Y axis nuts for adjustable nuts. (Now then, now THEN... titter ye not.) This involved stripping, (No. Listen, I've told you about this before... settle down.) down the mill, replacing the nuts
and reassembling, then adjusting the nuts and ways to reduce the backlash to manageable levels.
And now on to the battery compartment. A plastic sleeve and cap has beem machined to contain the batteries, which are two LI.Ion rechargeable batteries. Unfortunately these cannot be recharged in series. Therefore the handle has been modified with a bayonet fitting to allow easy removal of the batteries for replacement and recharging...
And finally for this episode- <ED. and about time too, oooof. thud.>
I warned him, I really did. -The gearbox. I have finally assembled this part, and it seems to work, although it seems to need more power than I hoped, with any luck that will improve with running in. The pinion gear has been soldered onto the output shaft of the motor as have the two gears for the two shafts that move the extending tube. It is a little rough but it works.
So what is left. Well the wiring needs to be finished. The final parts for the battery compartment need to be made and installed. All parts need to be polished and reassembled into their various assemblies, and then... I have to work out how to put it all together.
Are you ready for some pictures. and a link to a video...
Well first, the ongoing saga, Hitch-hiking around the Galaxy on 20 Altairian dollars a day.
... I stopped off on Earth a few days ago, and met an interesting chap, Wonko the Sane, he called himself. He told me about some travellers he met recently, Fenchurch and Arthur. We've met I said, small world was his riposte. As I left I helped myself to a couple of toothpicks and returned to the world of the insane.
the video.
ms sonic gearbox - YouTube
And the pics. (now where did that Editor go...)
tailgunner30uk
Active Member
Hi all. just a short update, a more comprehensive report at the weekend, hopefully!
So I have been working on the sonic over the last few weeks, but progress has been slow, with as many steps back as forward. The problems revolve around the switches that control the functions of the sonic. I have made several versions of the switch pcb and housing, but each time the parts simply will not fit. So on to plan??? there have been so many revisions and changes that I have lost count. The latest plan is to mount the switch pcb on the outside of the middle section of the screwdriver in a machined recess. Either surface mount tactile switches or a navigation switch will control the sonic. The motor will be controlled via a H-bridge on a custom pcb. The switches are 3mm square which promises hours of fun with a soldering iron.
Anyway that is all for now. Have fun and see you all soon.
So I have been working on the sonic over the last few weeks, but progress has been slow, with as many steps back as forward. The problems revolve around the switches that control the functions of the sonic. I have made several versions of the switch pcb and housing, but each time the parts simply will not fit. So on to plan??? there have been so many revisions and changes that I have lost count. The latest plan is to mount the switch pcb on the outside of the middle section of the screwdriver in a machined recess. Either surface mount tactile switches or a navigation switch will control the sonic. The motor will be controlled via a H-bridge on a custom pcb. The switches are 3mm square which promises hours of fun with a soldering iron.
Anyway that is all for now. Have fun and see you all soon.
tailgunner30uk
Active Member
... and then I said " I told him it was a bad idea!"
Oh, sorry about that, different... never mind, so hi all, how have we all been? That was a long break, to the weekend. I have however been working diligently, well somewhat diligently. well you know, doing something, occasionally.
This week I have been mostly working on, the control electronics, as I was last week, and last month. This has been taking somewhat longer than I had anticipated, hoped, expected, planned on!
The first idea was to simply use tactile switches to control the functions of the screwdriver. That didn't work as, as far as I can tell all tactile switches are single pole, any that are not are probably a similar size as the wart on Nanny McPhee's chin, and about as svelte. Therefore plan B. Using pairs of tactile switches to control the motor and provide a double pole simulacrum. Whilst this worked, I could not install it into the housing with the motor in place. Therefore plan C. Machining the motor housing, to allow the circuit board with the switches to fit. So out to the workshop, where as much space was made as possible to fit the controls, to no avail. Even with sanding down the board to not much more than the thickness of the copper tracks, still, no joy. Well there was always plan D. If tactile switches won't cut it then what about using a 'navigation' 5 way switch. Another redesign of the PCB, more soldering, then I hooked it up to test the switch and... Nothing, Now these things are a pain, surface mount with the pads mostly underneath the housing so I thought, aha! dry joints. Well I have some paint on silver based solder, I'll try that. A cocktail stick to apply the paste, and judicious use of a soldering iron and the solder went everywhere, creating bridged contacts underneath the switch where they were inaccessible to clean. So I tossed plan D into the bin, found a hammer and broke open the piggy-bank purchased a small vial of liquid flux and set forth on plan E.
Right plan E. I had such high hopes for plan E. It had all the right elements, a nice positive letter, plenty of experience, what could go wrong. Another PCB redesign, moved a small one amp H-bridge I.C. from it's own PCB, onto the control switch PCB. A shallow recess was milled into the outer surface of the motor housing. Then EUREKA! I do miss that show. I can build a battery monitor circuit to fit into the original slot where the switches, didn't fit. Another PCB designed and milled more electronic components bought more solder fumes sniffed. Assembling the battery monitor went quite well, and once done I tested it, and it worked. Awesome, great, I thought, I'm on a roll, plan E was IT. So I assembled the control PCB NAV. switch, H-Bridge, resistor to reduce current through the switch. Connections to a convenient small motor for testing. Multimeter to standby. Apply a little power and NOTHING!, what! again! I hung my head in shame, what more could I do I had pinned all my hopes on plan E, and it had let me down. What had I done wrong. It turns out that in the process of redesigning the circuit for the 6th 7th, 8th time, I lost count, I had rotated the orientation of the H-Bridge I.C. producing the obligatory facepalm so here it is. :facepalm
Plan F. What can I say, plan F had fail written all over it from the start. After another bout of redrawing the control board, making sure that the H-Bridge was the right way around this time, not using solder paste, applying copious amounts of flux and soldering everything up. I checked, then double checked all of the solder joints then affixed the connecting wires. Now when I was making the PCB I thought the traces were a little thin. Each time I have made a board they have got thinner. But this was verging on silly. Disaster expected, came, one of the connecting wires snagged and ripped the track right off the board. Putting a brave face on this event I reattached it further along the trace and tested the board. The motor turned. Although not in response to the position of the switch, and only when another, unrelated, track was grounded and stopped when the switch was depressed. I might note here that so am I.
Here we are then, Plan G. The magnificent 7 previous plans have bitten the dust. Plan G has two branches and really should be split into two. But I am starting to worry that I might run out of letters. Plan G.1 involves a redesign of the control PCB so that the H-Bridge inputs are pulled to ground when the switch is activated. Plan G.2 is to replace the NAV. switch with transistors and either very, very small tactile switches or touch pads. I know, every time I fail, my plans seem to become even more irrational, but what hey. If you're going to fail then fail spectacularly...
There was going to be a further tale of the galactic hitch hiker's travels. But he was unable to recount them as he was rolling about on the floor in hysterics at my woes. Schadenfreude, it's a ***** man...
Here are some pictures documenting my lamentable progress, and a Youtube video.
Making a PCB for the sonic screwdriver - YouTube
Oh, sorry about that, different... never mind, so hi all, how have we all been? That was a long break, to the weekend. I have however been working diligently, well somewhat diligently. well you know, doing something, occasionally.
This week I have been mostly working on, the control electronics, as I was last week, and last month. This has been taking somewhat longer than I had anticipated, hoped, expected, planned on!
The first idea was to simply use tactile switches to control the functions of the screwdriver. That didn't work as, as far as I can tell all tactile switches are single pole, any that are not are probably a similar size as the wart on Nanny McPhee's chin, and about as svelte. Therefore plan B. Using pairs of tactile switches to control the motor and provide a double pole simulacrum. Whilst this worked, I could not install it into the housing with the motor in place. Therefore plan C. Machining the motor housing, to allow the circuit board with the switches to fit. So out to the workshop, where as much space was made as possible to fit the controls, to no avail. Even with sanding down the board to not much more than the thickness of the copper tracks, still, no joy.
Well there was always plan D. If tactile switches won't cut it then what about using a 'navigation' 5 way switch. Another redesign of the PCB, more soldering, then I hooked it up to test the switch and... Nothing, Now these things are a pain, surface mount with the pads mostly underneath the housing so I thought, aha! dry joints. Well I have some paint on silver based solder, I'll try that. A cocktail stick to apply the paste, and judicious use of a soldering iron and the solder went everywhere, creating bridged contacts underneath the switch where they were inaccessible to clean. So I tossed plan D into the bin, found a hammer and broke open the piggy-bank purchased a small vial of liquid flux and set forth on plan E.Right plan E. I had such high hopes for plan E. It had all the right elements, a nice positive letter, plenty of experience, what could go wrong. Another PCB redesign, moved a small one amp H-bridge I.C. from it's own PCB, onto the control switch PCB. A shallow recess was milled into the outer surface of the motor housing. Then EUREKA! I do miss that show. I can build a battery monitor circuit to fit into the original slot where the switches, didn't fit. Another PCB designed and milled more electronic components bought more solder fumes sniffed. Assembling the battery monitor went quite well, and once done I tested it, and it worked. Awesome, great, I thought, I'm on a roll, plan E was IT. So I assembled the control PCB NAV. switch, H-Bridge, resistor to reduce current through the switch. Connections to a convenient small motor for testing. Multimeter to standby. Apply a little power and NOTHING!, what! again! I hung my head in shame, what more could I do I had pinned all my hopes on plan E, and it had let me down. What had I done wrong. It turns out that in the process of redesigning the circuit for the 6th 7th, 8th time, I lost count, I had rotated the orientation of the H-Bridge I.C. producing the obligatory facepalm so here it is. :facepalm
Plan F. What can I say, plan F had fail written all over it from the start. After another bout of redrawing the control board, making sure that the H-Bridge was the right way around this time, not using solder paste, applying copious amounts of flux and soldering everything up. I checked, then double checked all of the solder joints then affixed the connecting wires. Now when I was making the PCB I thought the traces were a little thin. Each time I have made a board they have got thinner. But this was verging on silly. Disaster expected, came, one of the connecting wires snagged and ripped the track right off the board. Putting a brave face on this event I reattached it further along the trace and tested the board. The motor turned. Although not in response to the position of the switch, and only when another, unrelated, track was grounded and stopped when the switch was depressed. I might note here that so am I.
Here we are then, Plan G. The magnificent 7 previous plans have bitten the dust. Plan G has two branches and really should be split into two. But I am starting to worry that I might run out of letters. Plan G.1 involves a redesign of the control PCB so that the H-Bridge inputs are pulled to ground when the switch is activated. Plan G.2 is to replace the NAV. switch with transistors and either very, very small tactile switches or touch pads. I know, every time I fail, my plans seem to become even more irrational, but what hey. If you're going to fail then fail spectacularly...
There was going to be a further tale of the galactic hitch hiker's travels. But he was unable to recount them as he was rolling about on the floor in hysterics at my woes. Schadenfreude, it's a ***** man...
Here are some pictures documenting my lamentable progress, and a Youtube video.
Making a PCB for the sonic screwdriver - YouTube
Last edited:
tailgunner30uk
Active Member
Just a moderately quick update.
I am still working on the electronics. At the present the battery monitor is working and operates when the activate button is pressed. I still haven't got the motor circuit to work, and this is proving to be a trial. I am not actually sure where I am going wrong at the moment, but it may be that the signal to the H-Bridge chip that I want to drive the motor is insufficient. There are a couple of things I can try. One thing I did notice was that I had the transistors incorrectly wired up which definitely didn't help.
Anyway, thanks for reading this and persevering with my lamentable humour. Please feel free to comment, offer suggestions, or just shake your head in disdain.
TTFN, more and better updates in the near future.
I am still working on the electronics. At the present the battery monitor is working and operates when the activate button is pressed. I still haven't got the motor circuit to work, and this is proving to be a trial. I am not actually sure where I am going wrong at the moment, but it may be that the signal to the H-Bridge chip that I want to drive the motor is insufficient. There are a couple of things I can try. One thing I did notice was that I had the transistors incorrectly wired up which definitely didn't help.
Anyway, thanks for reading this and persevering with my lamentable humour. Please feel free to comment, offer suggestions, or just shake your head in disdain.
TTFN, more and better updates in the near future.
tailgunner30uk
Active Member
Oooh, a series of short updates.
More on the progress of the electronics that form the heart of this sonic screwdriver.
After a few more trials, and failures I finally have resolved, for the most part, the problems with the control of the motor in the sonic screwdriver. The problem lay with my poor understanding of electronics mostly. But I have learnt a number of new things. Mostly that soldering irons are HOT! and should not be touched whilst on, anywhere but the handle.
So now the motor is controllable using switches for up and down. The battery monitor works, but needs some tweaking. I am going to use a Zener diode to regulate the voltage to the motor, as 5v seems to provide plenty of torque through the double gearbox to operate the mechanism.
From here it seems to be all down-hill and soon a new sonic will be born. As ever comments, advice, general laughter, are all welcome.
A short, and I do mean short video, and a picture for your enjoyment.
Thanks for stopping by.
Sonic screwdriver drive. - YouTube
More on the progress of the electronics that form the heart of this sonic screwdriver.
After a few more trials, and failures I finally have resolved, for the most part, the problems with the control of the motor in the sonic screwdriver. The problem lay with my poor understanding of electronics mostly. But I have learnt a number of new things. Mostly that soldering irons are HOT! and should not be touched whilst on, anywhere but the handle.
So now the motor is controllable using switches for up and down. The battery monitor works, but needs some tweaking. I am going to use a Zener diode to regulate the voltage to the motor, as 5v seems to provide plenty of torque through the double gearbox to operate the mechanism.
From here it seems to be all down-hill and soon a new sonic will be born. As ever comments, advice, general laughter, are all welcome.
A short, and I do mean short video, and a picture for your enjoyment.
Thanks for stopping by.
Sonic screwdriver drive. - YouTube
tailgunner30uk
Active Member
Thank you, the electronics have been a bane, going from simple switches to full on making pcbs, and designing circuits. When I started this part I wasn't even sure that I could drive the motor with enough power to operate the sonic. At least that part, I am now fairly confident will work.
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