Retrotechtacular: Making Enough Merlins To Win A War

From the earliest days of warfare, it’s never been enough to be able to build a deadlier weapon than your enemy can. Making a sharper spear, an arrow that flies farther and straighter, or a more accurate rifle are all important, but if you can’t make a lot of those spears, arrows, or guns, their quality doesn’t matter. As the saying goes, quantity has a quality of its own.

That was the problem faced by Britain in the run-up to World War II. In the 1930s, Rolls-Royce had developed one of the finest pieces of engineering ever conceived: the Merlin engine. Planners knew they had something special in the supercharged V-12 engine, which would go on to power fighters such as the Supermarine Spitfire, and bombers like the Avro Lancaster and Hawker Hurricane. But, the engine would be needed in such numbers that an entire system would need to be built to produce enough of them to make a difference.

“Contribution to Victory,” a film that appears to date from the early 1950s, documents the expansive efforts of the Rolls-Royce corporation to ramp up Merlin engine production for World War II. Compiled from footage shot during the mid to late 1930s, the film details not just the exquisite mechanical engineering of the Merlin but how a web of enterprises was brought together under one vast, vertically integrated umbrella. Designing the engine and the infrastructure to produce it in massive numbers took place in parallel, which must have represented a huge gamble for Rolls-Royce and the Air Ministry. To manage that risk, Rolls-Royce designers made wooden scale models on the Merlin, to test fitment and look for potential interference problems before any castings were made or metal was cut. They also set up an experimental shop dedicated to looking at the processes of making each part, and how human factors could be streamlined to make it easier to manufacture the engines.

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Hackaday Podcast Episode 294: SAO Badge Reveal, Precision On A Shoestring, And The Saga Of Redbox

With the 2024 Hackaday Supercon looming large on the horizon, Editors Elliot Williams and Tom Nardi start this episode off by talking about this year’s badge and its focus on modular add-ons. From there they’ll go over the results of a particularly challenging installment of What’s that Sound?, discuss a promising DIY lathe that utilizes 3D printed parts filled with concrete, and ponder what the implosion of Redbox means for all of their disc-dispensing machines that are still out in the wild.

You’ll also hear about custom macropads, lifting SMD pins, and how one hacker is making music with vintage electronics  learning kits. Finally, they’ll reassure listeners that the shifting geopolitical landscape probably won’t mean the end of Hackaday.io anytime soon, and how some strategically placed pin headers can completely change how you approach designing your own PCBs.

Check out the links below if you want to follow along, and as always, tell us what you think about this episode in the comments!

Download in DRM-free MP3.

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This Week In Security: The Geopolitical Kernel, Roundcube, And The Archive

Leading off the week is the controversy around the Linux kernel and an unexpected change in maintainership. The exact change was that over a dozen developers with ties to or employment by Russian entities were removed as maintainers. The unfortunate thing about this patch was that it was merged without any discussion or real explanation, other than being “due to various compliance requirements”. We eventually got more answers, that this was due to US sanctions against certain Russian businesses, and that the Linux Foundation lawyers gave guidance that:

If your company is on the U.S. OFAC SDN lists, subject to an OFAC sanctions program, or owned/controlled by a company on the list, our ability to collaborate with you will be subject to restrictions, and you cannot be in the MAINTAINERS file.

So that’s that. One might observe that it’s unfortunate that a single government has that much control over the kernel’s development process. There were some questions about why Russian entities were targeted and not sanctioned Chinese companies like Huawei. [Ted Ts’o] spoke to that, explaining that in the US there are exemptions and different rules for each country and business. This was all fairly standard compliance stuff, up until a very surprising statement from [James Bottomley], a very core Kernel maintainer:

We are hoping that this action alone will be sufficient to satisfy the US Treasury department in charge of sanctions and we won’t also have to remove any existing patches.

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Supercon 2023: Building A Portable Vectrex, The Right Way

The Vectrex was a unique console from the early 1980s. Developed by a company you’ve probably never heard of—Smith Engineering—it was put into production by General Consumer Electronics, and later sold by Milton Bradley. It was an outright commercial failure, but it’s remembered for its sharp vector display and oddball form factor.

The Vectrex was intended for tabletop use in a home environment. However, [Jeroen Domburg], also known as [Sprite_tm], decided to set about building a portable version. This wasn’t easy, but that just makes the development process a more interesting story. Thankfully for us, [Sprite_tm] was kind enough to tell the tale at the 2023 Hackaday Supercon.

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FLOSS Weekly Episode 806: Manyfold — The Dopamine Of Open Source

This week Jonathan Bennett and David Ruggles chat with James Smith about Manyfold, the self-hosted 3D print digital asset manager that’s on the Fediverse! Does it do live renders? Does it slice? Listen to find out!

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Silent Antenna Tuning

If you want to deliver the maximum power to a load — say from a transmitter to an antenna — then both the source and the load need to have the same impedance. In much of the radio communication world, that impedance happens to be 50Ω. But in the real world, your antenna may not give you quite the match you hoped for. For that reason, many hams use antenna tuners. This is especially important for modern radios that tend to fold their power output back if the mismatch is too great to protect their circuitry from high voltage spikes. But a tuner has to be adjusted, and often, you have to put a signal out over the air to make the adjustments to match your antenna to your transmitter.

There are several common designs of antenna tuners, but they all rely on some set of adjustable capacitors and inductors. The operator keys the transmitter and adjusts the knobs looking for a dip in the SWR reading. Once you know the settings for a particular frequency, you can probably just dial it back in later, but if you change frequency by too much or your antenna changes, you may have to retune.

It is polite to turn down the power as much as possible, but to make the measurements, you have to send some signal out the antenna. Or do you?

Several methods have been used in the past to adjust antennas, ranging from grid dip meters to antenna analyzers. Of course, these instruments also send a signal to the antenna, but usually, they are tiny signals, unlike the main transmitter, which may have trouble going below a watt or even five watts.

New Gear

However, a recent piece of gear can make this task almost trivial: the vector network analyzer (VNA). Ok, so the VNA isn’t really that new, but until recently, they were quite expensive and unusual. Now, you can pick one up for nearly nothing in the form of the NanoVNA.

The VNA is, of course, a little transmitter that typically has a wide range coupled with a power detector. The transmitter can sweep a band, and the device can determine how much power goes forward and backward into the device under test. That allows it to calculate the SWR easily, among other parameters.

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The 2024 Hackaday Supercon SAO Badge Reveal

We’ve been hinting at it for a few months now, running a series of articles on SAOs, then a Supercon Add-On Challenge. We even let on that the badge would have space for multiple SAOs this year, but would you believe six?

Way back in 2017ish, Hackaday’s own [Brian Benchoff] and the [AND!XOR] crew thought it would be funny and useful to create a “standard” for adding small custom PCB art-badges onto bigger conference badges. The idea was to keep it quick and dirty, uncomplicated and hacky, and the “Shitty” Add On was born. The badge community took to this like wildfire. While the community has moved on from the fecal humor, whether you call these little badgelets “SAOs”, “Simple Add-Ons”, or even “Supercon-8 Add Ons”, there’s something here for everyone. So if you’ve already got some SAOs in a drawer, bring them to this year’s Supercon and show them off!

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