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Old 01-14-2010 | 12:07 PM
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MinnFlyer
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From: Willmar, MN
Default RE: Hot wire cutting tips?

Sorry, I was unavoidably detained last night, so I never got to finish this. But I'm all done now.

For starters, I like to have a wooden dowel with a hole through it on each end so that you can "Hold" the wire for better control. Something else worth noting is that cutting a wing by hand is really a two-man job, so call a buddy over.

Now, make your templates. Plywood works, but something smooth like formica will cause less snagging of the wire. More importantly, leave tabs on each end for "Landing" spots.

Once you have the templates cut out, draw a centerline through them, then draw a vertical line at the start, end, and through the widest part (Lines 1,2 and 3). Line "3" is going to become our "Reference Line". (Note, the "reference line will vary with each wing. For this example. I am considering a standard wing

Now, draw another line centered between 1 and 3, and 2 and 3 (They don't have to be exactly centered, eyeballing it is good enough)

Keep splitting the lines in two until your lines are about 3/8" apart (Note, obviously, there will be more lines to the rear of line 3)

Do the same to your second template, but be sure to make the exact same amount of lines.

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Number the lines top and bottom on both templates (Both sides, because you'll be cutting a right and left wing) And drill two holes that a nail wil fit snuggly into. (Note that in my example, the reference line is now numbered "9", but your numbers may be different)

Take the measurements for "A", "B", "C" and "D"

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Now, cut your blocks to length and draw a reference line across the top and down both sides. Draw a centerline on each side.

Mark the measurements for "A", "B", "C" and "D" on their respective sides

Place a piece of straight plywood on each of the ABCD lines and hold each one in place with two nails (Drill snug holes in the wood for the nails first)

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Heat up your Bow and trim off the front and rear of the block

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Remove the plywood guides and put the templates in place. Be sure they are centered front-to-back and on the centerlines

Lay the block on a flat surface with some books or other weights on top so it won't move. Now, with one man on each side, lay the cutting wire on the landing tabs. Enter the block and start counting the line number (out loud) to each other as you cut so that you are both on the same number at the same time.

When you get to the landing tab at the end stay there for a few seconds! Do not move the wire because the center of the wire will be lagging behind slightly, so you want to both wait until the wire has completely cleared the foam before you move the wire away.

Now you can flip the block over (Leave it in the shuck that you just cut off as a cradle) and cut the other side.

Repeat for wing two, but don't forget to make it for the opposite side!
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