Build Log

Measuring the bottom of a pond through winter

We wanted a reliable record of the water temperature at the bottom of a pond throughout winter. I could not find an off-the-shelf setup I trusted for that job, so we ordered a digital probe from DigiKey that makes failures visible instead of silently giving a believable reading.

I designed a frog-shaped enclosure around the probe. Water can reach the sensing tip, and stainless steel washers embedded during the print give the enclosure enough ballast to sink and keep the probe submerged.

A separate printed keeper slides over the cable behind the probe shoulder. In the current CAD design, a small zip tie links the keeper to an eye on the frog, preventing it from lifting while allowing the probe to be removed later.

The supporting circuit is hand soldered on protoboard inside a small electrical box, then conformal coated. An outdoor USB-C wall adapter supplies power without bringing mains conversion into the box.

Green 3D printed frog enclosure with the metal temperature probe installed
The probe sits inside an open, water-facing shell.
The water-facing probe cage.
The separate piece slides behind the probe shoulder.
CAD assembly showing the probe through the frog housing, rear keeper, washer ballast, and the planned zip tie route in yellow
CAD assembly: probe, keeper, washer ballast, and zip tie route.View full size ↗
Front view of the frog-shaped sensor enclosure with drainage openings
Openings let pond water reach the probe.
Printing the weighted probe housing.
Hand-soldered protoboard and wiring inside the electrical box
Hand-soldered, conformal-coated electronics.
Closed electrical box with cable glands and orange mounting tabs
The electronics in a compact enclosure.

A zipper duct for a diesel heater

We wanted to pipe warm air from a diesel heater into a tent without leaving the zipper open to the cold. Starting from a zipper-duct reference, I modeled an adapter that slides over the tent edge: a groove captures the zipper, while the round cuff connects to the heater hose.

The print turns that opening into a controlled air path. A later compact revision reduced the zipper footprint while keeping the passage open through the round-to-oval transition.

Black printed duct seen from the side, showing the groove that holds the tent zipper
The groove grips the zipper edge.
Round-to-oval airway and zipper groove.
Looking down through the round opening of the printed heater duct
The round hose cuff opens into the tent passage.
Printing the duct.