Modifying a cordless drill to house a car horn and compressor requires careful planning and execution. This guide outlines the steps involved in transforming a standard cordless drill into a portable air horn. The project focuses on achieving a clean, integrated look by fitting a single, shorter horn within the drill body and mounting the compressor on top.
Creating Space for the Horn
Begin by joining the two halves of the drill body. Using a 1/2″ drill bit, create a hole at the back of the drill casing. This hole will accommodate the rear of the car horn. Carefully enlarge the opening with a file, ensuring a snug fit for the horn without forcing it into place. Precision is key to avoid damaging the drill body.
Mounting the Compressor
The compressor mounts to the top of the drill body. While the compressor has a mounting lug designed to fit into an existing cavity on the drill, some modification is usually necessary. Although filing the drill’s opening is an option, removing material from the compressor lug itself using a flap wheel on an angle grinder offers a more efficient approach. Gradually remove material from the lug until the drill halves close seamlessly with the compressor in place.
Securing with Hose Clamps
Two hose clamps secure the compressor to the drill. The drill’s direction selector switch opening serves as one mounting point, requiring no modification. For the second clamp, utilize the bottom vent hole originally intended for the drill’s motor. This location avoids interference with the horn inside the drill body. Widen the vent hole with a file until the hose clamp fits comfortably. Ensure the clamp can be tightened securely without obstructing any other components.
Finalizing the Assembly
Once all components are in place, ensure all connections are secure and the drill halves close properly. Test the horn’s functionality by connecting the drill battery. This modification transforms a standard cordless tool into a unique and functional air horn. This project demonstrates how a simple cordless drill can be repurposed with some ingenuity and basic tools.
