Angle cutting and fitting foam...

[GPW]

Angle cutting Foam ... that’s what we have to do if we don’t want any curves... but by cutting several angles and putting them together we can get really close to a curve visually and aerodynamically ... It all seems really easy ... just measure the angles and cut the foam, glue them together .... But the problem is , if you’re cutting and trying to join two different angles , suddenly nothing fits, one is always too big ...
Always thinking about a generic trailer that would look good , be aerodynamic and yet be just a box (for maximum space) with angle cut curved nose . Foam pieces that could be cut on the flat and then assembled .. Getting the angles right must be the secret . Once precision angle cutting is learned, we can have any manner of ‘curved’ construction with angled flat pieces ... easy things like angled (peaked) roofs for the rain to roll off.. Curved walls ... doors ..

Once the angles are all figured out (and how to cut them) , it might be cool to have the pieces interlock too ... (slots and tabs sorta’ thing) ... The whole design could be cut on CNC , making a foam shell (kit so to speak) you could assemble in a few hours... with just some glue and pins (or bamboo skewers)...

Maybe the best way is to start small , so I’m going to work on a generic “Nose” ... something to be added to streamline "your basic Box camper ” ...
Anybody have any ideas and wanna’ help ... that would be Cool too ...

Here’s some possibilities of Nose profiles... and a typical section ..

[GuitarPhotog]

Look into hot wire cutters for your foam. They'll make precision cuts that are difficult (or very messy) with other tools.

<Chas>

[GPW]

Been hot wiring for years on planes (RC) and the FoamStream .. as you say , it really is the best way ...

[wagondude]

The one thing you have to remember for the angles, is that both mating surfaces have to be cut to half the total angle. In your plan view above, the first angle you show is a 45 deg mated to a 90 deg. In reality, those should be both cut to 22.5 deg for them to mate without one face being wider than the other. In absence of an adjustable hotwire jig, a table saw would be most accurate even though you would have to deal with the foam dust. It gets even more tricky when you want to do compound angles.

[lthomas987]

Have you looked into stave built boat masts? Or birds mouth? There are a ton of calculators on the web and good ideas for making curves out of straight cut pieces.

I will find links when I am back home.