Runs and Embedded Linux Media Server.

Working Wifi Painting. Embedded Router.

(Submitted by Car Lust reader Julian Santa-Rita)
I have been naming my cars since my first one. Each is its own personality to me. My first was a grey Volvo 240 with velour seats, and I named it ” Nigel.” Later a 1986 RX-7 I named “Chu-Chu Rocket” passed through my hands. There was a Subaru GL called “Roo-Badoo” and a MKII Jetta who was renamed loads of “happy expletives,” depending on whether one or both of us was in a saucy mood that particular moment.
But it took me almost a year to understand my Saab 9000 Aero well enough to finally give it the pet name “E.M.,” which was shorthand for “Executive Missile.” The relationship began as I left college to move to my new home 1,000 miles away, and I needed to replace the “expletive” Jetta. My father brought me to see this somewhat awkward silver Saab which I’d never even heard of before and I’d certainly never seen one in person. Someone had traded it in on a Subaru WRX.
Its rakishness and creases were not immediately beautiful to my young eyes, though its designer dipped his ink to pen some of my favorite legends like the Lotus Esprit, VW Golf, DeLorean DMC-12, and BMW’s M1 Supercar.
My Saab was no DMC-12 with its bulbous 5-door hatchback shape and 3-spoke wheels, I thought, but it seemed to drive with a new tier of urgency. The right(chous) pedal contained threatening levels of acceleration… levels which DeLorean drivers often find lacking in their stainless steel steeds. Even early Esprits would be found tested and lacking. In fact, around this time most of my “cool” friends were getting Celicas and Mustang GTs, but none of them were near as quick as the weird little 5-door I’d discovered almost completely by accident. In the first week, I’d realized that this was a true sleeper car in the performance department, despite its extreme comfort and sensible hatchback, when I found it listed on supercars.net.
This, it turned out, was a real driver’s car… rewarding every input, reacting accordingly to every subtle input change, and in time of need I could fit a whole refrigerator in the hatch. Pictured is an 8-foot futon couch. Eat it, U-Haul.
I owned the sweet little Saab for 6 years. I used it to move all of my things across the country, take me to job interviews, travel around town, and elsewhere. This little supercar sedan set me up in my adult life. I did my own maintenance (sometimes frequently) and eventually my own tuning with software I found online for free (t5suite).
One thing that Saab has is a loyal following of smarty-pants nuttier types who are very willing to share their insanity and knowledge. Within two years my sleeper had sway bars, more boost, better brakes, better cooling, and a few other niceties which enhanced the driving experience alongside the typical maintenance.
It taught me how to treat it along the way, even responding ever so slightly to old oil, and every sensation of the driving experience seemed communicated so cleanly to the cockpit. We went on road courses, off-road to campsites, on date nights, and ran errands together.
E.M. was one of those rare perfect pieces of design, a wondercar capable of utility, speed, comfort, reliability, passion, and it was never too old to teach a young guy a few things about overall goodness of design. I reluctantly sold E.M. because of a leaking sunroof and growing mileage count. Like so many, I thought I needed a newer model.
We were best friends for 6 years, and I traded E.M. in on an Audi Wagon, for which I will never forgive myself.
I last tracked her to Stilwell, O-Kay-lahoma, where I’m sure her heart still beats for someone. If you see her around, please say hello for me, as I think of her often.
–Julian Santa-Rita
Image Credits: Thanks to Julian for the images of the Saab.

- Preview of the final ‘New Hotness’ Portable Party Machine! 50,000 songs+
For something going on 40 years this cabinet looked like some variation on the ratty image pictured next and not the shiny bauble above. It was capable of playing one record at a time and storing a dozen or so albums. This is an illustrated tale of how it came to reunite me with my music collection and frustrate audiophiles.
Like many of my favorite things, this was discarded in someone’s trash. The smart money might have been on leaving it there, but my wife Lori wanted it immediately, else I was going to be the item the trash.Getting it home, we soon realized that most of the components did not in fact work. Also, the box is not squared anymore, and furthermore there’s not a wal-mart in the land that sells glass for tube amplifiers. Not one!

- Test fit is promising, but it still looks like a dry turd!
So I quickly took it’s NF guts out, and tossed in some spare PC parts( of the back of my closet variety). Suddenly it’d play any lossy-compressed song we’d feed it, but our hunger was left wanting.This could be functional, cooler, far superior to the original version, but suiting the same purposes. With itunes and the “remote” app, volume, tracklists, and so on could even be controlled from our cell-phones…
It was starting to tie the room together, man!

- Build it out. Here she’s measuring to make sure a wooden VESA mount will work out.
My wife has become the voice of refinement in my house, which is to say, when we’re ready to burn the bridges, she’s there making sure we have enough matches and gasoline. Here she’s measuring to make sure a VESA mount will work out, but at this point Lori had already cleaned the wood and replaced the speaker grille fabric on the front. This took a near-total teardown of the original box, short of replacing the veneer, but allowed some much needed repairs.

- Here, her mounting rails for the fabricated top-plate and monitor are shown as the PC buildup begins again.

- This is the void we have to work with (and the new fabric).
Big gaping hole of potential. You could fit a dead body or 50,000 songs in there. We went with songs…this time… The goal being to keep everything looking mostly normal, but to have a machine that would play out a music mix anywhere we plugged it in, with no setup beyond that. This way we can take it to parties and it will DJ for the evening.

- Loaded up, and ready to roll.
So, like any case-mod-esque project, we have a PC. You see it In the rightmost void we fit the whole PC (RAID 2×36GB, 500GB filestore, bluetooth, wifi, PSU and,fans, bliky lights and the two high-frequency speakers. The woofer and it’s case/volume control are mounted in the leftmost void. The speakers have been replaced with a 3-piece component system for a PC with a standard 3.5mm Jack as line-in. It’s not anything worth writing to Audiophile magazine about, but it’s heads and shoulders above the NF tube amp and paper-cones I’m replacing and was probably 35$ brand new. Not fancy, but for our lossy mp3’s we’re fine with it… we came to party, not pick out nuances.

- Lori’s Plexiglas Panels fom Ponoko.com even accommodate for the warped and off-square box. Lori had to special order hardware small/long enough to put it all together properly.
Once the main bits are all in place, it really needed something befitting of its new life as a ‘moddern’ digital device. My wife drew up and ordered two Plexiglas panels which stack to create a nice steeped effect. It also allowed us the freedom to incorporate a USB port (for phones/usb keys) and on/off power switch into the top panel. For 30$ or so we can order other colors, etc. Her panels were designed to make use of an apple keyboard and track-pad, both blue-tooth. There is a non-existent driver to run Apple Bluetooth devices on windows vista located deep in a compressed file on an OSX disk. We used that file to make them work on vista.

- In order to get WIfi Signal to be decent I had to run an external antenna.When closed, the new fabric and tiny antenna popping off of the back belie it’s conversion. I think it looks good, and heck I’d put an antenna on my head if I wouldn’t pick at it all day.

- All in all the only item we paid for outright for this project were some new fabric, Plexiglas panels and a few $$$ worth of PC parts. The real benefit has been the ability to listen to our music without having to use our laptops or hooking up something to the TV. An ipod dock-speaker it is not, but they don’t make ipod big enough for our whole collection, and this thing matches our living room.

another view

- The end.

This machine is now in its second major revision: I got a deal on some lithium cells from Barefoot Motors (Jamie from Mythbusters’ ATV company) Lucky day, they also came with a balance charger.
Lithium Batteries, Tail-section and Lighting, better cooling and so on.It has a new gear ratio as well. Top speed and acceleration have actually both increased. The previous gearing was simply too tall.

Lower tray expanded by David Davidian of Ironman Fabrication, who also welded the original lead acid tray. Tail section is my first attempt at fiberglass.

Show and tell. This is everything at a glance. The new cells are so strong that when fully charged they actually hit V+ cutoff on the controller. I’m skipping a cell for the time being and considering using it to run accessory cooling. You can still see the tank tabs from the previous iteration’s plexiglass side covers.

This is my favorite touch. My wife Lori made all of the wooden pieces on the V.1 design and this is how she’s treated the tank’s fill-up door. Wood panel with control switches and 48v voltmeter.

Fill ‘er Up!

here is a test fit using Jon Panichella’s Collada frame (slightly modified) and the finalized layout for the lithium cells.

testing variations and determining whether to chop the frame up or build it out

early tests just rendered on top of v1.0 bike from a photo and loosely scaled based on specifications found online for wheel diameters, etc
Fun for all, old and new! This one’s easy, so get HACKING(or send me your helmets)!!!

Fully Functional Helmet on Mostly functional Human
This is a military helicopter helmet that i found for 22$ at a thrift shop. I like it so much I bought two.
It has re-purposed electronics so that it works with a Playstation3 or Cell phone via bluetooth, and has a complete second circuit integrated to output to a an RF-wireless headset that is also routed through the original system’s speakers. The combination allows for a unique helmet that allows me to both have the ambient video-game sounds as well as chat-communications integrated into a single helmet for gaming, but also allows me to use it as a regular bluetooth, radio, or wireless headset form the TV when the wife isn’t awake yet. This project is straightforward, but to look GREAT it takes some time. One major advantage is that you’re updating very old technology with very new. New stuff is smaller so you have decent working space to hide it all.
The Helmet:
It’s speakers were made Sept 11, 1984 (reusing them because they’re cool and work), Other pieces say 1993. It’s has a U-174/U input connector wired. The original Electret Microphone from the Gub’ment was an amazing piece of noise-cancelling wizardry, but I decided against using it, opting to extend the wiring the the bluetooth headsets original pickup and wiring the sound to the right speaker(arbitrary).This is mostly because i would have had to create a phantom-power circuit for it..and i was lazy that day.

The original wiring of this is for MONO mic and MONO headphones from a theatrically large 4-pin analog u174 connector. I split the loom to the speakers to allow stereo (’cause gaming takes advantage and it’s better, dammit!)

New wires run to speaker cup and to stock headphone wires. RED/BLK to SPKR+-, YEL/GRN to mic +-
Supplies+rundown:
1 ) Helmet with integrated Analog headset (tear it down, locate speaker wires, dissect electret microphone plastic and solder in the mini-microphone from the bluetooth headset on short (pre-attach these) wire leads to the electret’s stock +- pins ).

Bluetooth with wire extensions, U174 Mic connector, Original Electret Microphone being glued back together with new (from bluetooth headset) condenser mic in it. This gives you perspective on the tiny-ness of the Bluetooth. Pity it just wouldn't fit IN the original electret mic.
2) bluettooth wireless headset (you’re extending the reach by running leads from the mic+- and speakr+-. Mine is a Jwin branded unit which are about 10$ on a good day. Good thing too these things are TINY and ROBOTS did the soldering the first time so I messed one up easily. Short of abducting a child I was able to solder the tiny connections by leaving an exacto blade between the terminals to curb solder flow between the “please-bring-a-microscope” terminals. The speaker terminals have wire leads already and if you’re gentle you can solder to THOSE for the speaker leads. extra care with the mic/spkr soldering regardless, and I suggest reinforcing with hot glue.

Tiny bugger. silver rectangle is the battery, black bit is the stock speaker(I've snipped it off), and the reddish blur area at the top right of the board is the bluetooth's microphone, wee bastard. that's a real human thumbnail for caparison.
3)spare wire. i suggest using different colors of wire. My wire is from some retired CAT5 or telephone cable. plenty of color options in there.
4)soldering kit- solder new leads to the speakers and run them through the stock wiring pass-though on the headphone cups.
5) hot glue kit- used this to both melt a spot fin the polystyrene for, and to glue in place the bluetooth dongle. Use hot glue liberally. I reinforced all of my micro-tiny solder points with hot-glue to keep their fragile connections intact under a little bit of wiggle pressure.

Hotglued in place, i'll use the tape to keep the hot glue formed correctly, and keep the Bluetooth from moving as glue cools. This location lines up with a small hole in the helmet so i can activate the on/off button it while weaing the helmet.
6) For BONUS POINTS you should also acquire a RF-wireless headset and wire it in as well. I found a set that allowed the battery and board to fit in the stock cups behind the stock speakers for 14.99 that ALSo has an AM/FM RADIO!! FANCY PANTS!!! This step wasn’t really that bad. or even much different from the other steps above. Just add a new lead to each speaker, but directionally isolate signals to them by adding an inline commercial headphone splitter or some diodes to keep them from back-feeding into each others output electronics. If there is much interest in that portion of the build, I’ll get something posted, though it’s mostly a matter of hot-gluing the RF board and battery into each speaker cups, runing thee wire and drilling a hole to access the on/off switch. . .
Hello Dr. Mills! This is OUR squirrel!



