I made a hot-wire jig to make a pretty large radius in the nose of my slide-in camper. There are two wires shown in the photo, the rectangular one was being used to cut a chunk out of a piece, and I slipped the curved wire in to re-create the radius curve used earlier. This could be easily modified to make a tighter radius.
![Day 36jig2 copy.JPG](./download/file.php?id=19808&sid=3ae9fb2965a941f3eb4b25e24e3555da)
- Day 36jig2 copy.JPG (171.73 KiB) Viewed 1438 times
![Day 36 copy 2.JPG](./download/file.php?id=19809&sid=3ae9fb2965a941f3eb4b25e24e3555da)
- Day 36 copy 2.JPG (152.54 KiB) Viewed 1438 times
I had used a trim router to start removing material from a piece of foam, but quickly realized the benefit of a hot-wire cutter. I've made more than a dozen different jigs to do different cuts. It's so much cleaner. (ghcoe has been my inspiration on that subject [http://www.tnttt.com/viewtopic.php?f=55&t=54099&start=75].) I also use the Stanley pocket plane for cleaning up less professional cuts I've made.