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Old 02-24-2007, 08:00 PM
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stupidaso
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Default Foam wing core woes

I'm about halfway through my first scratch build. What is holding me up now is cutting the foam wing cores.

I built a good hotwire cutter, made templates out of countertop laminate, and am using eps foam.

I have cut several cores, they all come out with the center of the core thinner than the ends. i.e., the root and tip are acurate to the templates, but the wing gets thinner as you move toward the center.

I am working on a flat surface, the wire is tight, heat seems ok. Wire is 0.020 ss fishing wire, cuts very well with the dimmer switch on my cutter at about half-way.

It is only a 24-inch core, I am at my wit's end as to why they keep coming out so poorly.

Has anyone had this problem, or does anyone know what's going on? I really appreciate any help, I'm about ready to chuck the whole project.

Thanks,
Stu.