Hot Wire Foam Cutting ....

[GPW]

For many years now we’ve been building airplanes , on a smaller scale, but planes none the less... Hot wired from the old Blue Styrofoam ! Really an easy method to cut foam into various shapes ... much less messy than carving or sawing ...

Many You Tube videos on the subject .. I just thought this one was a good example of what you can do ... http://www.youtube.com/watch?v=2C8aDkDlgcA Thinking especially how quick you could do “kerf-ingâ€

[pete42]

looks similar to the one we used when building our "real" foam and fiberglass airplane.
where he used pattern on blue foam to cut the wing shape we used aluminum ones held on with small nails
that had numbers spaced every so often ours was a two man job his looks very well thought out.
his pattern was for a Cessna 182 model
I use to fly several 182's at our local jump club crazy people would actually jump out when ever I took them aloft

Pete

[GuitarPhotog]

I just can't see the sense in leaving a perfectly good aircraft in mid-flight

We used a hot-wire foam cutter in the florist shop where I grew up in the 50s to make forms for wreaths and similar funerary floral arrangements.

I'm thinking about making a small one with a very deep throat for cutting my styrofoam insulation.

<Chas>

[GPW]

Pete ... “ airplanes is airplanes “ .. some are just bigger... Same methods apply !!

GP, It is Quick and Easy !!! ... and the leaves and grass have finally covered up the foam dust and bits in the yard generated from the last build ... using the carving and sanding method ...

As I mentioned previously , I really think this method would really be Super for Kerf cutting .. That could be a messy and somewhat dangerous job with a saw or router...

[atahoekid]

[quote="GPW"]
Thinking especially how quick you could do “kerf-ingâ€

[GPW]

Mel, I was thinking like Pete said ... Templates on each side ... Simple really , and you could make the templates with the exact angle to allow the foam to bend/close to the exact radius you want ... Just a few calculations ... For depth control , just put the appropriately thick board on each side ... as a â€

[bonnie]

Hotwire sells the tools and a stand/rack/whatever it's called to hold the tool at an angle. Seems to me it would work for a variety of cutting angles and could be mounted to a wood block for downward angles.

i think I'm going to save to get the cutting tools I think I will need to accomplish what I'm planning. Right tool for the job and all that.

[GPW]

Bonnie , although their tools look excellent , you can easily make your own HW Bow , and out of scraps ... nothing to it ... you need plans ??? An old model train transformer works for a power supply .... although I use an old Variac...
We actually used to hang /suspend our bow over the cutting table with a rope/pulley /counterweight ... very convenient ... and Simple ..

[GPW]

oops DP...

[GPW]

Here’s the kind we always make ... been using these for 40 plus years now to cut foam for wings etc. ... Make it to the size you need ...

[pete42]

atahoekid you reminded me we did use a Weller soldering gun with a copper wire
we used it to "scoop" out the seat foam and on the end of the wing for the running light pad.

GPW yep same deal only larger is right your drawing of the foam cutter looks like what we built it too was powered by a train transformer.

once the cutter was built a jig could be figured out to cut foam
two V shaped patterns mounted on a table so the cutter's legs would hit the table at the bottom of the cut.
go down one side of V with the wire come up and out the other side, slide foam repeat cuts nice and clean.

maybe a better way of explaining is hold your fingers in the "peace sign" slide one finger on the other hand down one side of the V up the other.

sometimes my descriptions are clear as mud.

Pete

[atahoekid]

Ahaa! Now it makes sense. Once I saw GPW's sketch it all made sense. Don't think I have an old transformer around. Time to go to Craig's List. I may even try the old solder gun thing.

[GPW]

Pete, peace sign , that’s just perfect !!!!

Mel, it’s really easy once you do it ...

[allan1]

Here’s the kind we always make ... been using these for 40 plus years now to cut foam for wings etc. ... Make it to the size you need ...

Since I don't own a transformer, I'm wondering if my laptop power adapter (19.5 volts @ 3.34 amps - using a dimmer to control temperature) would be a possible substitute. I hate going out and spending money if I can adapt something to be multi-use. Gonna try an internet search.

[GPW]

An old toy train transformer works great ... pretty cheap used ... probably in thousands of attics ... gathering dust ...