The best way we found to cut the foam is very simple and effective. This method uses a nichrome wire that is heated by a power supply and it cuts right through the foam like a hot knife in butter. You can buy a foam cutter, but you you can get your hands on a variable power supply, you can make your own. This basic design is to give you an idea how to build one, from these basics you can build a larger one. It is always a good idea to test and practice on a scrap piece of foam.
*Warning* We are not responsible if you burn yourself on the hot wire, or if the wire would break and hurt somebody. Use in a well ventilated area!
Material Required
Nichrome wire(available in a hobby shop)
2 small wooden dowels
1 larger wood dowel
Variable power supply(must supply at least 1 amp and 9 volts)
Small wire
Assembly
The following pictures show a simple foam cutter which cutes up to 6 inches wide, this setup may be modified. A light spring may be added to keep the wire tight, when the wire heats up it expands and becomes a little loose.
- Drill 2 holes in the handle the size of the dowels
- Add glue in the holes and insert the dowels, let dry
-Drill the small holes near the tip of the dowels, attach nichrome wire in the holes, a light spring may be added and this moment
-Attach 2 small wires(coated) from each end of nichrome wire, attach to your power supply
-Use only in a well ventilated area, do not touch the nichrome wire, raise the voltage until it gets warm enough to cut the foam, the wider the cut the more voltage you will require. The power supply i use is 0-18 volts, 1.5 amps, i set it at approx 6-9 volts to cut.
