Homemade Hot Wire Foam Cutter for $30-40!
11-07-2006, 11:35 PM
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Homemade Hot Wire Foam Cutter for $30-40!
I'm preparing to put one of my first fiberglass kits into production and wanted to try making the plug out of fiberglassed foam. I researched home built hotwire foam cutters on RCU but didn't find anything to my liking so I went www surfing and found [link=http://www.instructables.com/id/EK8Q92824BEP286S6S/?ALLSTEPS]THIS[/link]. Pretty much followed the directions except I added a 120V red LED as a power indicator and made the "wand" out of PVC (figures 1-4). Works excellent and the dimmer switch regulates the temperature of the hotwire. Check out the test cut (figure 5).
Mods
Mods
11-07-2006, 11:53 PM
#2
RE: Homemade Hot Wire Foam Cutter for $30-40!
I have some at the supplies at home. The radio shack 24 volt, 2amp transformer and the light dimmer switch. I am putting a fuse between the main line and the power supply for safety. Where did you get the plastic box? I purchased a similar size one, except metal. The pvc tubing should work for a bow. Someone was and has suceeded to sell $5.00 worth of electrical pvc conduit as a $30.00 cutting bow. Just can't believe it. The versions I have of sw are too old and don't have the sketch picture function in the tool bar, so I am sketching up the profiles in autocad and importing these. In fact there is a conflict with the video drivers on my new pc to sw 2001. If I create a series of profiles in a sketch; go to the loft tool bar, the profiles "disappear" on the screen.
I your threads very informative.
I your threads very informative.
ORIGINAL: Mods-R-Me
I'm preparing to put one of my first fiberglass kits into production and wanted to try making the plug out of fiberglassed foam. I researched home built hotwire foam cutters on RCU but didn't find anything to my liking so I went www surfing and found [link=http://www.instructables.com/id/EK8Q92824BEP286S6S/?ALLSTEPS]THIS[/link]. Pretty much followed the directions except I added a 120V red LED as a power indicator and made the "wand" out of PVC (figures 1-4). Works excellent and the dimmer switch regulates the temperature of the hotwire. Check out the test cut (figure 5).
Mods
I'm preparing to put one of my first fiberglass kits into production and wanted to try making the plug out of fiberglassed foam. I researched home built hotwire foam cutters on RCU but didn't find anything to my liking so I went www surfing and found [link=http://www.instructables.com/id/EK8Q92824BEP286S6S/?ALLSTEPS]THIS[/link]. Pretty much followed the directions except I added a 120V red LED as a power indicator and made the "wand" out of PVC (figures 1-4). Works excellent and the dimmer switch regulates the temperature of the hotwire. Check out the test cut (figure 5).
Mods
11-07-2006, 11:55 PM
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RE: Homemade Hot Wire Foam Cutter for $30-40!
ORIGINAL: Jim_Purcha
I have some at the supplies at home. The radio shack 24 volt, 2amp transformer and the light dimmer switch. Where did you get the plastic box? I purchased a similar size one, except metal. The pvc tubing should work for a bow. Someone was and has suceeded to sell $5.00 worth of electrical plastic tubing as a $30.00 cutting bow. Just can't believe it. The versions I have of sw are too old and don't have the sketch picture function in the tool bar, so I am sketching up the profiles in autocad and importing these. In fact there is a conflict with the video drivers on my new pc to sw 2001. If I create a series of profiles in a sketch; go to the loft tool bar, the profiles "disappear" on the screen.
I your threads very informative.
I have some at the supplies at home. The radio shack 24 volt, 2amp transformer and the light dimmer switch. Where did you get the plastic box? I purchased a similar size one, except metal. The pvc tubing should work for a bow. Someone was and has suceeded to sell $5.00 worth of electrical plastic tubing as a $30.00 cutting bow. Just can't believe it. The versions I have of sw are too old and don't have the sketch picture function in the tool bar, so I am sketching up the profiles in autocad and importing these. In fact there is a conflict with the video drivers on my new pc to sw 2001. If I create a series of profiles in a sketch; go to the loft tool bar, the profiles "disappear" on the screen.
I your threads very informative.
I bought project box from radio shack for $8.50. Sorry about SW, but design anyway you can!
Mods
11-08-2006, 07:04 AM
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RE: Homemade Hot Wire Foam Cutter for $30-40!
For those interested in foam cutting, here's another link that shows how to build a cutter for about $30 and there's a good video within the how-to column. I know the author and can attest to his expertise in foam cutting, vacuum bagging, etc.
http://www.rcgroups.com/forums/showthread.php?t=462759
http://www.rcgroups.com/forums/showthread.php?t=462759
11-08-2006, 04:09 PM
#6
RE: Homemade Hot Wire Foam Cutter for $30-40!
Here was another good link:
http://www.nsrca.org/technical/tip_t...wer_supply.htm
The project box is no longer available from Radio Shack as of this spring. This is design I was planning to build for foam wire cutting. The use of the dimmer switch, removes the need for the circuit board, potentiometers etc.
http://www.nsrca.org/technical/tip_t...wer_supply.htm
The project box is no longer available from Radio Shack as of this spring. This is design I was planning to build for foam wire cutting. The use of the dimmer switch, removes the need for the circuit board, potentiometers etc.
ORIGINAL: Mods-R-Me
A fuse! I know I forgot something [:@].
I bought project box from radio shack for $8.50. Sorry about SW, but design anyway you can!
Mods
ORIGINAL: Jim_Purcha
I have some at the supplies at home. The radio shack 24 volt, 2amp transformer and the light dimmer switch. Where did you get the plastic box? I purchased a similar size one, except metal. The pvc tubing should work for a bow. Someone was and has suceeded to sell $5.00 worth of electrical plastic tubing as a $30.00 cutting bow. Just can't believe it. The versions I have of sw are too old and don't have the sketch picture function in the tool bar, so I am sketching up the profiles in autocad and importing these. In fact there is a conflict with the video drivers on my new pc to sw 2001. If I create a series of profiles in a sketch; go to the loft tool bar, the profiles "disappear" on the screen.
I your threads very informative.
I have some at the supplies at home. The radio shack 24 volt, 2amp transformer and the light dimmer switch. Where did you get the plastic box? I purchased a similar size one, except metal. The pvc tubing should work for a bow. Someone was and has suceeded to sell $5.00 worth of electrical plastic tubing as a $30.00 cutting bow. Just can't believe it. The versions I have of sw are too old and don't have the sketch picture function in the tool bar, so I am sketching up the profiles in autocad and importing these. In fact there is a conflict with the video drivers on my new pc to sw 2001. If I create a series of profiles in a sketch; go to the loft tool bar, the profiles "disappear" on the screen.
I your threads very informative.
I bought project box from radio shack for $8.50. Sorry about SW, but design anyway you can!
Mods
11-08-2006, 05:41 PM
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RE: Homemade Hot Wire Foam Cutter for $30-40!
ORIGINAL: Jim_Purcha
Here was another good link:
http://www.nsrca.org/technical/tip_t...wer_supply.htm
The project box is nolonger available from Radio Shack as of this spring.
Here was another good link:
http://www.nsrca.org/technical/tip_t...wer_supply.htm
The project box is nolonger available from Radio Shack as of this spring.
ORIGINAL: Mods-R-Me
A fuse! I know I forgot something [:@].
I bought project box from radio shack for $8.50. Sorry about SW, but design anyway you can!
Mods
ORIGINAL: Jim_Purcha
I have some at the supplies at home. The radio shack 24 volt, 2amp transformer and the light dimmer switch. Where did you get the plastic box? I purchased a similar size one, except metal. The pvc tubing should work for a bow. Someone was and has suceeded to sell $5.00 worth of electrical plastic tubing as a $30.00 cutting bow. Just can't believe it. The versions I have of sw are too old and don't have the sketch picture function in the tool bar, so I am sketching up the profiles in autocad and importing these. In fact there is a conflict with the video drivers on my new pc to sw 2001. If I create a series of profiles in a sketch; go to the loft tool bar, the profiles "disappear" on the screen.
I your threads very informative.
I have some at the supplies at home. The radio shack 24 volt, 2amp transformer and the light dimmer switch. Where did you get the plastic box? I purchased a similar size one, except metal. The pvc tubing should work for a bow. Someone was and has suceeded to sell $5.00 worth of electrical plastic tubing as a $30.00 cutting bow. Just can't believe it. The versions I have of sw are too old and don't have the sketch picture function in the tool bar, so I am sketching up the profiles in autocad and importing these. In fact there is a conflict with the video drivers on my new pc to sw 2001. If I create a series of profiles in a sketch; go to the loft tool bar, the profiles "disappear" on the screen.
I your threads very informative.
I bought project box from radio shack for $8.50. Sorry about SW, but design anyway you can!
Mods
11-08-2006, 07:45 PM
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RE: Homemade Hot Wire Foam Cutter for $30-40!
ORIGINAL: Jim_Purcha
You're using the abs project box , not the all metal box p/n#270-253, which was discontinued. What part number did you purchase?
You're using the abs project box , not the all metal box p/n#270-253, which was discontinued. What part number did you purchase?
11-08-2006, 08:06 PM
#10
RE: Homemade Hot Wire Foam Cutter for $30-40!
Sure it's not the [link=http://www.radioshack.com/product/index.jsp?productId=2062285&cp=2032058.2032230.203 2276&allCount=9&fbn=Price%2F%246.00+-+%249.99&fbc=1&fr=StorePrice%2FRSK%2F00000600%2F00 000999&parentPage=family]270-1809[/link]
Radio Shacks no longer exist in Canada, most got bought out by "The Source". It still carries some of the radio shack stock. Not like the old days in Radio Shack.
Radio Shacks no longer exist in Canada, most got bought out by "The Source". It still carries some of the radio shack stock. Not like the old days in Radio Shack.
11-08-2006, 10:18 PM
#12
RE: Homemade Hot Wire Foam Cutter for $30-40!
The photo on the radio shack must be wrong, it looks to narrow to be the yours. What are you using for wire. Nichrome? Doen't the ABS box get hot? The original 270-253 project box had vents for hot air.
11-09-2006, 05:50 AM
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RE: Homemade Hot Wire Foam Cutter for $30-40!
ORIGINAL: Jim_Purcha
The photo on the radio shack must be wrong, it looks to narrow to be the yours. What are you using for wire. Nichrome? Doen't the ABS box get hot? The original 270-253 project box had vents for hot air.
The photo on the radio shack must be wrong, it looks to narrow to be the yours. What are you using for wire. Nichrome? Doen't the ABS box get hot? The original 270-253 project box had vents for hot air.
11-09-2006, 06:24 AM
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RE: Homemade Hot Wire Foam Cutter for $30-40!
I had a spare guitar string in my case, so I measured the resistance. A 42 inch wire only had 2.5 ohms resistance. By my calculations, that means you could easily overrun the current rating of the 24v 2a transformer. Has anyone measured the actual current necessary to heat a steel guitar string to the right temperature? I'm thinking a lower voltage, higher current transformer would give better dynamic control of the wire heating.
Brad
Brad
11-09-2006, 07:40 AM
#15
RE: Homemade Hot Wire Foam Cutter for $30-40!
I even thought of purchasing this wire for foam cutting: [link=http://www.skykingrcproducts.com/accessories/foamcutterwire/renewire.html]Rene Foam Cutting wire[/link]
I'll try this after nichrome wire.
I'll try this after nichrome wire.
11-09-2006, 07:50 AM
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RE: Homemade Hot Wire Foam Cutter for $30-40!
ORIGINAL: Jim_Purcha
I even thought of purchasing this wire for foam cutting: [link=http://www.skykingrcproducts.com/accessories/foamcutterwire/renewire.html]Rene Foam Cutting wire[/link]
I'll try this after nichrome wire.
I even thought of purchasing this wire for foam cutting: [link=http://www.skykingrcproducts.com/accessories/foamcutterwire/renewire.html]Rene Foam Cutting wire[/link]
I'll try this after nichrome wire.
11-09-2006, 09:51 AM
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RE: Homemade Hot Wire Foam Cutter for $30-40!
I am now (and have been for years and years) using single strand stainless steel fishing leader. No problem. I am also using the power supply I built from the plans mentioned above. It is the latest in a long string of power supply/transformer setups I have lashed together and it works the best so far. Get the parts from Mouser or AllElectronics, forget Radio Shack. It has become the home of toys and telephones instead of an electronic hobbyists store.
Tom
Tom
11-19-2006, 02:51 PM
#19
RE: Homemade Hot Wire Foam Cutter for $30-40!
Picked up a 270-1807 case today. Very inexpensive, only $5.99. All the other components I have at home. Still debating between getting a triac and making the pcb or just using the dimmer switch. Dimmer switch would probably make it quicker to fabricate. How's your cutting samples using rene wire coming along? Are you happy with your power supply? I'll probably work on mine next weekend when I'm at home.
ORIGINAL: Mods-R-Me
Either one will work, but I have the 1807
Either one will work, but I have the 1807
11-19-2006, 03:21 PM
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RE: Homemade Hot Wire Foam Cutter for $30-40!
ORIGINAL: Jim_Purcha
Picked up a 270-1807 case today. Very inexpensive, only $5.99. All the other components I have at home. Still debating between getting a triac and making the pcb or just using the dimmer switch. Dimmer switch would probably make it quicker to fabricate. How's your cutting samples using rene wire coming along? Are you happy with your power supply? I'll probably work on mine next weekend when I'm at home.
Picked up a 270-1807 case today. Very inexpensive, only $5.99. All the other components I have at home. Still debating between getting a triac and making the pcb or just using the dimmer switch. Dimmer switch would probably make it quicker to fabricate. How's your cutting samples using rene wire coming along? Are you happy with your power supply? I'll probably work on mine next weekend when I'm at home.
ORIGINAL: Mods-R-Me
Either one will work, but I have the 1807
Either one will work, but I have the 1807
12-17-2006, 09:13 AM
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RE: Homemade Hot Wire Foam Cutter for $30-40!
anyone have a part number at Radioshack for a fuse they would recomend ? Im heading there this morning and have no clue :>
12-17-2006, 11:00 AM
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RE: Homemade Hot Wire Foam Cutter for $30-40!
ORIGINAL: btomlinson
anyone have a part number at Radioshack for a fuse they would recomend ? Im heading there this morning and have no clue :>
anyone have a part number at Radioshack for a fuse they would recomend ? Im heading there this morning and have no clue :>
and a [link=http://www.radioshack.com/product/index.jsp?productId=2102786&cp=&origkw=fuse+holder &kw=fuse+holder&parentPage=search]Fuse Holder[/link]
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12-18-2006, 10:06 AM
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RE: Homemade Hot Wire Foam Cutter for $30-40!
I have a few questions :
I'm going to install a cooling fan... I assume I need a 24v fan and install it on the 24V output side of the transformer ?
I was thinking about some sort of panel meter or light to show the power setting.. Would I need something that shows in amps, watts or volts ? and what range ?
I'm going to install a cooling fan... I assume I need a 24v fan and install it on the 24V output side of the transformer ?
I was thinking about some sort of panel meter or light to show the power setting.. Would I need something that shows in amps, watts or volts ? and what range ?
01-05-2007, 07:49 AM
#24
RE: Homemade Hot Wire Foam Cutter for $30-40!
The original design had a 1 amp fuse installed. The transformer is 2 amps. So your panel meter shouldn't be more than 2.0 amps. You could put another light between the transfomer and the cutting wire after the dimmer switch.
01-17-2007, 12:18 PM
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RE: Homemade Hot Wire Foam Cutter for $30-40!
ORIGINAL: Newc
For those interested in foam cutting, here's another link that shows how to build a cutter for about $30 and there's a good video within the how-to column. I know the author and can attest to his expertise in foam cutting, vacuum bagging, etc.
http://www.rcgroups.com/forums/showthread.php?t=462759
For those interested in foam cutting, here's another link that shows how to build a cutter for about $30 and there's a good video within the how-to column. I know the author and can attest to his expertise in foam cutting, vacuum bagging, etc.
http://www.rcgroups.com/forums/showthread.php?t=462759
Here's a useful article from RCU:
http://www.rcgroups.com/forums/showthread.php?t=558772
some highlights:
1. new train model transformers aren't the way to go; some old ones are okay
2. A good way to go is a 12V or 24V transformer from All Electronics.com on a dimmer. 12 volts is probably sufficient for up to a couple of feet. 24 is preferred for big stuff. (You need the same amps either way, but more volts for longer wires. You can finesse this a bit by using very thin wire, but people seem to prefer 16- or 18-gauge stainless steel. It's strong enough to crank pretty taut for striaght cuts.)
3. a lot of people prefer stainless steel to nichrome for hot wire cutters. You can get a roll of 16- or 18-gauge stainless wire from Cabela's for about $9. (And you get hundreds of feet of it! Give some away.)
4. regular guitar strings are pretty low resistance, so you'll need more amps from your power supply if you use them. You can get stainless guitar strings, but you can't beat the cost of the wire from Cabela's.
5. You can gang two RadioShack transformers (or other transformers) of the same make and model together to get twice the amps. (That's what I did, when I decided I wanted 4 amp capability to cut dense and/or strange foams.) But usually it's easier to buy one higher-amp transformer from allelectronics, and costs about the same.
Paul
