10' Standie Foamie ... on hold

[atahoekid]

As far as the radius, how about using a piece of PVC pipe? Using a tablesaw, you could rip a 90-degree slice of the pipe. Attach sand paper to the inside radius of the sliced pipe. This would give you a profile.

Now you're talking. Simple but should be real effective. Tom you're a genius... I was thinking about building jigs and all kinds of stuff like that and the obvious escaped my mind.

I think a short piece will be good to get it roughly down to size and then a long one to "fair" it all together.

Brilliant, Tom!!!

[Dusty82]

How much of a radius are you shooting for? Nobody has mentioned the obvious - a round over bit in a router. I've seen bits for sale with up to a 2" radius, and that's pretty big for a router bit. Of course you need router with a 1/2" collet, but that's not a big deal. If you don't have that big of a router or can't borrow one, several places rent them for a reasonable price. You wouldn't need it for more than a couple of hours.

I have 1" radius round over bits that fit a 1/4" collet, so I know they're pretty inexpensive. I picked up a cheapy Skil round over bit set (1/4" radius, 1/2" radius, and 1" radius) at Lowe's for something like $30. They'd zip right through that foam.

[mikeschn]

I've never tried a router on EPS. I wonder if it cuts cleanly?

Mike...

[pjo129]

Mike, great job so far. I just caught up on this thread. This is very similar to what I'm planning (only in my mind so far).

I love the keyhole idea and the recessed floor.

[Rosey]

Mike,
I used a router on my boat yesterday. Did not have a bit with as big of a radius as you need, but it worked great! Cut smooth and went through the foam like it was nothing.
Rosey

P.S. It did make a huge mess. Little flecks of pink stuff everywhere!

[mikeschn]

Mike,
I used a router on my boat yesterday. Did not have a bit with as big of a radius as you need, but it worked great! Cut smooth and went through the foam like it was nothing.
Rosey

P.S. It did make a huge mess. Little flecks of pink stuff everywhere!

That's good info Rosey... I'll have to pick up a router bit and give it a try.

Thanks,

Mike...

[DJT]

As Rosey said, router works very well on foam. Also great way to make openings for windows etc with a ledge/bevel/backstop quick and easy!

[Dusty82]

People have been using CNC routers on all kinds of different foams for years with fantastic results. I've cut several different types of foam with a router, and it works great on EPS. Yeah, it makes a holy mess, but it cuts very cleanly. Just know that the sharper the bit you use, the better. Oh - and to help keep the "foam dust" from clinging to you due to static electricity (which WILL build up as you rout,) ground yourself to dissipate the static. I wrap a grounding strap (a couple of bucks at Radio Shack) around my ankle and clip the alligator clip to one end of a set of jumper cables, which are then clamped to a good ground source. It doesn't totally eliminate the whole "I'm a pink/blue snowman" look, but it sure helps. A quick blow down with the air nozzle while still grounded takes care of the rest.

If you're only looking for something like a 3/4" to 1" radius, Lowe's carries those bits for a reasonable price - around $10 apiece, IIRC.

I can't for the life of me remember who it was, Mike, but someone here on the board ran some EPS through a planer because they couldn't find the right thickness locally. It worked great, but it made a huge pink mess all over their shop. Kind of stands to reason, I guess...

[Wolffarmer]

I have been thinking more and more about getting the 2hp dust collector from Harbor Feight. Will have to see when the foam starts flying

Randy

[vwbeamer]

Watching, this is really interesting.

[mikeschn]

Well, I just took a quick look at router bits. I went to MCLS.

The largest bit I can get with a 1/4" shank is 1/2" radius. I think that's too small for that edge.

GPW, what side radius did you sand into your foamie?

Mike...

[swampjeep]

Mike, have you given thought to making one of them foam hot cutters with a wire? GPW was talking about them , I would think you could have the wire bent in the rad you want, and have it held in a block of wood that could also be a guide, and cut that rad on the foam, no big mess to clean up that way either.

[GPW]

Here’s an idea .... you need to make the wire pretty stiff , but only have to heat it enough to melt/cut the foam , NOT red hot ...

[swampjeep]

GPW, that's pretty much exactly what I had in mind, but I don't remember all the parts for makign the "hot knife" I know it wasnt' much. just the music wire, holder, and somethign to regulate the current, that's teh part I forget what to use, but I'm sure there's a number of ways/things to regulate the current.

[pete42]

I built most of two fiberglass airplanes both the two man kind not the hobby style.
I used a hot wire powered with a toy train transformer to cut all kinds of shapes wing ribs, canard, seat ect.

when cutting the foam the correct heat to apply to the wire was one that produced "hairs" when cutting to hot the foam melts to cool and the wire drags.

Mike you are right 1/2 inch round over bit would not give you the look you want I'll check my router drawer and see if I have a larger one.

I think a 2 inch radius would look good and let the cloth wrap around nice and flat, a coke can is 2 inches across so 1 inch radius may work.

but cutting the sharp corners off and sanding may be the best way one wrong move with a hot wire and zappo you have a repair to do.