Teardrops n Tiny Travel Trailers

One of the messiest jobs I have done so far was cutting the channels for the wire. After laying out the pathway with a marker, I took the router to the insulated walls. Before I knew it, my safety glasses were coated with the pink foam; the small bits were stuck to about everything in the garage. I had the pathways cut in no time, worked great.

I would recommend this method to anyone planning to run wires in the wall, however, wear mask, goggles, and I used ear protection.

Be prepared for a longer clean up time, than the actual cutting.

Earl,

Sorry about the fuzzy mess. Next time, pull out your propane torch and heat something like an old screwdriver and just drag it through the foam. It'll make an ugly looking channel, but it'll be covered up when you skin your tear.

Thanks Chris, good idea. I'll probably do that if I need to add any more channels.

Chris C wrote:Next time, pull out your propane torch and heat something like an old screwdriver and just drag it through the foam.

I like bending the thicker type of coat-hanger wire into the section shape I want to cut and heating that. It doesn't cut for long before it needs heating again, but you can put a bend in the wire to rest on a piece of wood next to the channel you want to cut, so you get a straight channel with a constant depth.

Andrew

Yup, that'll do'er too! But you can also hook a rehostat (sp?) to the two ends of the wire and make a continuous cutter. It works, I've done it.

A pistol-type soldering gun with some wire connected to the 2 posts in the shape you want works well too. Wire not as thick as a coat hanger.....more like baling wire. I think even 14ga solid electrical wire will get hot enough to melt the foam.

Ed

I use a single edge razor blade...on single wires...just 1 pass and stuff the wire into the foam...for bulk wires 2 passes 1/4 " apart and pick out the chunks with your finger...just what I've done...Doug

I have an old pencil type soldering iron somewhere and a new one I bought recently. If I can find the old one, I'll use it to make my wire channels. Thanks for the hot cutting suggestion.

Chris C wrote: Next time, pull out your propane torch and heat something like an old screwdriver and just drag it through the foam. It'll make an ugly looking channel, but it'll be covered up when you skin your tear.

Great hint Chris !!! I'll remember that one !!! [/b]

I'll have to cut foam to fit between framing, spars, etc., but I think I'll run my wiring, tacked, stapled (carefully), or tied to the wood, then fit in the foam so I don't have to make grooves in it. I'll be working in my "Portable garage" outside, so I won't have to worry about the foam particles messing up the house. It will blow into the neighbors yard.

Dale,

Just cut it with a sharp knife. Works fine and no "fuzz".

Chris, the hot iron idea is great, as is the blade to cut, however, it can't be as much fun as flinging pink foam bits everywhere!

To be honest , wish I would of thought of it, but at least the router went through the foam and the wood in a single motion. I will however use the blade and or heat to enlarge or re-route as needed.

cracker39 wrote:....but I think I'll run my wiring, tacked, stapled (carefully), or tied to the wood,.....

A hot melt glue gun works great to attach the wires to the wood so they are out of the way to put in the foam

I've built with several different types of foam for a number of years and I use an old dual range pistol grip type soldering gun. I removed the copper tip and replaced it with a piece of nichrome wire. The wire can be shaped any way you want it. When cutting channels for wiring you can shape it to be round or square, etc. Much like the hot wire method of cutting foam only on a smaller scale.

While we're on the foam insulation subject, how do you adhere the foam to the underside of the floor? especially after coating it with roof tar, etc?
Liquid nails? or have to screw/nail it to stay in place?

Julie