Foam cutter

[oldatheart]

I finaly got off my butt and made this.
Just scrap wood, cheap 24 volt transformer and a dimmer switch.
I screwed in 2 eyebolts for the wire and 2 more on the back side to run a rubber band "high tec" to keep tension on the wire. Simple as can be.
If any one wants more photos or details please ask

 

[Brad]

That looks pretty slick. I have always used an electric knife. That looks like it would be far easier and neater.

 

[minmax]

That is great!!

 

[Ian]

Looks like that beats using a fillet knife, my foam-cutting jobs always looked like a 5-year-old did them except for the Pelican cases with the pre-cut grids. Where do you buy the wire?

 

[oldatheart]

The wire came from the hobby store.
The best part is all the foam guns!

 

[Rick]

I would love to see more photos, the description of how it works in the OP just didn't sink in.

 

[oldatheart]

I will take more photos soon.
The build is very easy.
I used a small transformer
25 v 2 amp
And all you do is hook up a circuit through the wire using the dimmer to control output.
Wood frame to insulate the circuit.

 

[oldatheart]

I will take more photos soon.
The build is very easy.
I used a small transformer
25 v 2 amp
And all you do is hook up a circuit through the wire using the dimmer to control output.
Wood frame to insulate the circuit.

Chicken scratch

 

[Brad]

Looking at the first photo I can now see the wire. Makes more sense now. Looks like a table with the wire in the middle so the foam can be laid flat and slid around while the wire does the cutting.

Pretty slick. Beats the hell out of any form of knife. Bet it is faster and far neater too.

 

[oldatheart]

Yep you got it!
And it's fun for the whole family!

Ps if the gun sits to low take the cutout and slice it in half to put in the case to raise it.

 

[Ian]

I get it now, it's an electric scroll saw, just punch a hole, thread the wire through, tension it with the rubber band, turn on the juice, and cut on the dotted line. Very cool.

 

[oldatheart]

That's it.

 

[Rick]

Ah-Ha . . .

Suddenly it makes perfect sense. Yes, very cool.

 

[Ian]

Now I know what I'm going to do with that scrap of Formica I have laying around, and that new bench I just built in the garage. I can make a fixture for a removable arbor and just drill a half-inch hole through the middle of the formica-covered part to attach the wire under the bench when needed. Some foamboard-backed foam cutouts made into inserts for a couple of my soft rifle bags will cure some banging-around issues I have. Now, where to get the foam?

 

[Brad]

Got a fabric store nearby? The ones around here carry foam in a variety of thicknesses.

 

[oldatheart]

I have even used the white styrofoam it cuts very well and is free. Works for things that are not used much. Also some guns come in cardboard boxes with egg crate foam.

 

[Ian]

Hmm. I'm "foam ignernt", I thought the polyurethane stuff used for mattresses and cushions was different from the stuff used in protective cases. Guess it doesn't matter if the hot wire will cut cleanly.

 

[Brad]

It is largely a matter of density. The stuff in most gun cases is much more firm that regular foam sold in most fabric stores but that just means you need a thicker layer to allow for the extra compression.

I think a polystyrene foam insulation would make a neat way of filling the extra space in a gun case too. Use it for some padding but add a layer of foam rubber for gripping and holding the firearm.

The possibilities are endless

 

[Pistolero]

Built my airplane with a foam cutter. Used .032 304 SS safety wire. Works great. Mine was on a
movable frame, not like a jig saw. Good design for cutting flat foam like that, but I was making airfoil
contours.

Bill

 

[Ian]

Is the foam the structure, or was it for patterns?