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Hot wire foam cutter

Old 10-12-2011, 04:59 PM
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goirish
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Default Hot wire foam cutter

Does anyone have any pictures or plans for a hot wire foam cutter that would work for cutting wings. Also what size wire and power supply do I need.
Old 10-12-2011, 05:06 PM
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Gray Beard
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Default RE: Hot wire foam cutter

Gene, there was a thread in the last year of one a fellow made with a HOW TO. It was slick. Looked like something even I could use.
Old 10-12-2011, 08:20 PM
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Campgems
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Default RE: Hot wire foam cutter

There is a Yahoo group, "CNCFoamcutters" that will make your head hurt will all the information.

A couple guys at our club wanted me to make one, but it is cheaper to buy the foam already cut unless you are going to make a big bunch of wings. There is some free software listed on the site for cutting wings and turtle decks and about anything else you can think of. While I was toying with the idea, I decided that if I were to build a CNCRouter, I could put a second Gantry on it and use it for foam also. That idea may come tofruition one of these days.

We have a guy who does some really nice foam cutting manually. For tapered wings, he projects the LE and Te out to a point and uses a long wire from there to the root pattern. It isn't quite a accurate as a CNCcutter, but it does work.

Icut my first foam core back in 1970 using patterns cut from Formica and a long bow. Itturned out so well that I've never done another.

Don
Old 10-13-2011, 03:16 AM
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Default RE: Hot wire foam cutter

Gene, here's mine. The bow is made from PVC and the power supply is made from a 24vdc transformer and dimmer switch (all from Home Depot)

The wire is .020 Stainless Steel that I bought on line.
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Old 10-13-2011, 03:30 AM
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Default RE: Hot wire foam cutter

thanks Minnflyer. How well does it work? Trying to build the wing for my gull wing Cobra and it is giving me a pain in the you know where. I think foam would be the way to go. I have to go to Home Depot today anyways so I may pick up the items I need and do some practicing and see if I can do it. I will post some resultsgood or bad.
Old 10-13-2011, 03:58 AM
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Default RE: Hot wire foam cutter

It works great
Old 10-13-2011, 09:21 AM
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Default RE: Hot wire foam cutter

You also need to get the correct type of foam too I've been told before.
Old 10-13-2011, 09:32 AM
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Default RE: Hot wire foam cutter

I've accumulated these over the years:
http://www.mackrc.net/patternwings2/index.htm
http://tysplanes.com/how_to_videos
http://www.rcuniverse.com/magazine/n...roduct_id=3815
http://www.rcgroups.com/forums/showthread.php?t=462759
Old 10-13-2011, 10:42 AM
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Default RE: Hot wire foam cutter

Here is a couple of pictures of the items that I purchased for the foam cutter. How do I wire it up. What goes where.
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Old 10-13-2011, 11:10 AM
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Default RE: Hot wire foam cutter

I use a battery charger for power, it works fine. i like Minflyers better though. More control.
Old 10-13-2011, 02:19 PM
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Default RE: Hot wire foam cutter

Check out this link

[youtube]http://www.youtube.com/watch?v=KXWWnPIhk44[/youtube]

[youtube]http://www.youtube.com/watch?v=jM8U4WZ2klg&feature=related[/youtube]


I used a 2 amp fuse.

Jim
ORIGINAL: goirish

Here is a couple of pictures of the items that I purchased for the foam cutter. How do I wire it up. What goes where.
Old 10-13-2011, 03:46 PM
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Default RE: Hot wire foam cutter

Like this
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Old 10-13-2011, 04:52 PM
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Default RE: Hot wire foam cutter

HUMMMMM!!!! me thinks I have a bad transformer. Won't get hot. Can't feel anything in the transformer when I plug it in. So back to Menards. Love it, when all those places are over an hour away.
Old 10-13-2011, 05:26 PM
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Default RE: Hot wire foam cutter




ORIGINAL: goirish

Does anyone have any pictures or plans for a hot wire foam cutter that would work for cutting wings. Also what size wire and power supply do I need.
You might find these links on foam cutters, power supplies. etc useful:

http://www.rcgroups.com/forums/showthread.php?t=462759
http://www.rcgroups.com/forums/showthread.php?t=558772




http://www.rcuniverse.com/forum/m_58...tm.htm#5858217



http://www.rcuniverse.com/forum/m_67.../tm.htm#670783



http://www.rcuniverse.com/forum/m_49...tm.htm#4968914

Old 10-13-2011, 05:37 PM
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Default RE: Hot wire foam cutter

I have seen them made with old electric train transformers.
Old 10-14-2011, 04:35 AM
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Default RE: Hot wire foam cutter


ORIGINAL: MinnFlyer

Like this
I'd use a double pole switch and put it on the input side of the transformer, switching both black wires. Your way will have the transformer drawing current whenever the system is plugged in. Wasted money.
Old 10-14-2011, 06:09 AM
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Default RE: Hot wire foam cutter

True, but it's only plugged in when it's in use. I like to have the switch right at the bow so I can turn it off easily before setting it down
Old 10-15-2011, 03:28 AM
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Default RE: Hot wire foam cutter

Hoorayyyyyy!!!! Minnflyer does that foam cutter work good. thanks for the help to all. I am now in business. I made one very lite bow from a 1/4" oak dowel and one from the pvc pipe. ended up using a radio shack 25.5v transformer. Put it in a project box with a neon light and fuse holder. If ya dress the part, ya gotta look smart
Old 10-15-2011, 03:35 AM
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Default RE: Hot wire foam cutter

Cool!
Old 10-15-2011, 04:34 AM
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Default RE: Hot wire foam cutter

Now I know where to send my foam cutting work to.
Old 10-15-2011, 08:34 AM
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Default RE: Hot wire foam cutter


ORIGINAL: bruce88123

Now I know where to send my foam cutting work to.
Me too, when I try it the foam looks like Shakey Jake tried to work before his 6 pack of beer. Can't wait to see some of your work with it.
Old 10-15-2011, 08:44 AM
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Default RE: Hot wire foam cutter

My bow was made from a 3/4 wood dowel and some 1/4 in wire(like for landing gear ) from the LHS. Drill holes in the dowel at an outward angle so when the wire is attached it will spring outward keeping the wire tight.

I've found for cutting wing cores two people is a help. One on each end of the wire. I divide up my templates into "numbered sections" The same number of sections on each template. One person is the "master" and calls out the number as you cut. The "helper" just keeps pace with the master. If you're cutting a tapered wing, the root template may have the sections spaced 1/2 inch apart. The tip template may have the sections spaced 1/4 inch apart, 10 section on each template. As I said, the key is to have the same number of sections so both of you end at the same time and the wire tracks uniformly on both templates.

I hope this makes sense.

Ken
Old 10-15-2011, 08:48 AM
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Default RE: Hot wire foam cutter

Haaaa! will only show you the good stuff. Have been trying it out and I am surprised at how easy the wire goes through the foam. Made my wing rib profile out of formica. Did I spell that right?
Old 10-15-2011, 08:51 AM
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Default RE: Hot wire foam cutter

kenh3497 Makes sense to me. My wife didn't understand it, but I did.
Old 10-15-2011, 09:28 AM
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Default RE: Hot wire foam cutter


ORIGINAL: goirish

Haaaa! will only show you the good stuff. Have been trying it out and I am surprised at how easy the wire goes through the foam. Made my wing rib profile out of formica. Did I spell that right?
You can make your templates out of wood amd put Chrome furnice tap on the edges. Will not burn the wood and easyer to make.

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