FoamStream...

[GPW]

Back from HF , got the small trim router ... @ $28.00 , not bad .... we’ll see if it works ...

[Ned B]

Got bits?

[mezmo]

What about the spiral cutting bits like is used in a Rotozip
tool ?

It'd probably fit in the small router as long as you have the
size collet with that to fit it. It just might have the bit length
to give you the depth of cut you need. A straightedge
fence/guide would be needed, as I'm sure you know...[They
really tend to wander otherwise in my view.]

Cheers,
Norm/mezmo

[GPW]

Ned, I got the bits too !

Norm , got the guide , but was “wandering" about that ... the Fat jigsaw blade wandered a bit too ...
 We’ll try it out this morning ... on some scrap first .... yet another “test” .. .

[GPW]

OK, now we’re Kerfing !!!  ... The trim router just walks through the foam quickly , the little edge guide working fine ... I did find the cutting part on my bit wasn’t deep enough for the full 2.5” depth cut at once , tried that and some foam melted onto the smooth top part of the bit ... So I’ll have to do it in two passes ... No problem . This is much easier than the jigsaw, not as temperamental as the hotwire ... Still messy , but no way around that eh ???

[linuxmanxxx]

Glad to help buddy cheap and easy is good.

[Mary C]

Yea!!!

Mary C.

[Ned B]

looking good. hogging out material that deep, you pretty well have to do it in two passes, no matter if it is foam or especially wood.

[GPW]

Yeah, this is really much easier than the other way ... even after two passes I did have to pass a dowel down the grooves to dislodge all the caked foam bits left ... once vacuumed out the cuts were deep and clean and the panel bends nicely ... Funny about the kerfs , even the left over foam dust caked/lodged deep in the kerfs can restrict the bending ...
Well, that’s two panels down , two to go

[CampsALot]

Do you fill the kerfs with glue when you install the panels?
Just thinking of future projects....

Warren

[GPW]

Naa, just left em empty ... too much trouble for something that’s to be covered up ... Now if I was cutting the exact V kerfs that would close completely on bending , that might be worth gluing ..

[GPW]

Cutting the last kerfs 2nd pass (deep) on the LAST panel ... Long Day ... HOT outside ...90F ... foam beads everywhere ... but it’s ALMOST done ... Only problem is I did the experimental cross kerfing (hot wire test) on the last 3.5” panel , so I had to kerf a 4.5” panel and will get out the HW bow and slice it to size... Then we should be ready to glue on all the rest for the cabin hopefully tomorrow .... and then comes the nose ...

just in time too as all the news stations this morning were ablaze with hurricane season get ready preparations and warnings ... It’s supposed to be an ACTIVE season ... that really means nothing , it only takes the one ...

[GPW]

Today will be the big test ... the first time we install the kerfed panels onto the full 36” radius part of the skeleton . Just to keep things Simple , I’ve been using T2 all along to glue the foam to the framework. It does dry fairly quick , and all the foam to plywood and foam to foam joins are solid... Don’t think T2 would work as well with Blue or Pink ... just guessing ... Just getting light enough to chase the skeeters’ off.. still fairly cool .. sorta’ 83F ... and here goes ...

[GPW]

And now it’s Raining !!! ...

Edit: Now it’s supposed to Rain all day and night ... There goes that plan ...

[GPW]

Clear this AM . Third level panels going on .... due to the curve , the bottom has to be glued solid first ... Thinking now I should have used Gorilla Glue for just that. Quicker , and gap filling , although I’m counting on the shrinkage of the canvas to pull everything together super tight in the end ...