guys,

normally whether we cut foam with a knife or hotwire, it is very difficult to make a perpendicular cut. The problem is acute when the foam thickness increases to 10cm or beyond. In my case I need to cut 1.5" thick foam.

So the question is how does one make a neat perpendicular cut?

Hi normal knife will not give you dizered result, use hot wire cutter.

First draw your parts on cardboard and cut 2 same parts
then with help of temp. glue or allpins attach cardboad shape and then cut it.

Can post pics pics if u wanna see

hmm, but for a 40mm thick foam, cardboard is OK?

Use cardboard or any thick thing. like box with smooth edges, and these things only for support dear,

unable to upload pics, check out following my Home Made Hot Wire Cutter Video

i would suggest u to use a surgical knife....! they are damn sharp.! cuts foam like soft butter..

instead of cardboard use thin cheap ply..!( easy to cut and hard)

thats neat. What wire do you use, gbisht? have you tried cutting a wing ?

Hi,

I am using Guitar "E" string, 1st string of guitar.
I have tryed so many wires but they didnt work, and finally I bought it in 20Rs.

no I have not made wing because I dont have EPP foam, but yes wing is not a big deal, if you practice on Hot wire cutter
but 2side support is important for quality cut.

I am new in Plane Hobby, so can you tell me can we made plane with normal theracol sheet available at book store.
I have built micro plane but for middle size plane I am not sure.

http://www.rcindia.org/rc-people/hi-all-6659/msg77900/#msg77900

 yes you can.....its quite simple. just need some practice......and patience.

there are many ways of building and strengthening and over time you will develop your own. spend some time going over the scratchbuilts on this forum....as you get more comfortable with the material....you will do better and better....good luck