DIY Hot wire foam slot/ knife/ scoop cutter

samayaraj · October 29, 2016, 11:14:56 AM

Hi all RC enthusiast!

I have made a tool to cut foam boars of various profiles such as rectangular, square, round or any specific shape as per your need.

I have given this tool in instructables.com http://www.instructables.com/id/DIY-Variable-Depth-Hot-Wire-Foam-Scoop-Cutter/

I have uploaded video in youtube

Look at it and make it in your workshop use this tool to reduce your load on fine foam cutting!

samayaraj · October 29, 2016, 11:17:51 AM

More pictures of my foam cutter

K K Iyer · October 29, 2016, 09:24:33 PM

@samayaraj sir,
Spar groove cutter and CF tube hole cutter...
Excellent.

Regards.

(BTW, where did you get that pink foam from?!)

samayaraj · October 30, 2016, 08:29:40 AM

Dear Mr. KK Iyer,

Thanks for your correction

. I was bit confused how to name it.

I bought the pink foam board (Ovens corning Foamular board) through a dealer called Aditya marketing, chennai. Please look at their web http://www.insulations.net.in/

sanjayrai55 · October 30, 2016, 10:10:26 AM

Nice innovation

Iyer sir, what is the specific advantage of pink foam?

K K Iyer · October 30, 2016, 10:18:08 AM

No idea, sir. Only seen it on RC Groups etc.
Seems denser and firmer than thermocol.
OP may know...

saikat · October 30, 2016, 11:52:36 AM

good work - you make it seem deceptively easy.
you are quite advanced as I can see by your setup .

what are the spindles attached to the edge of your table ?
some sort of guide for your hot wire cutter ?

samayaraj · October 30, 2016, 04:09:05 PM

Quote from: K K Iyer on October 30, 2016, 10:18:08 AM
No idea, sir. Only seen it on RC Groups etc.
Seems denser and firmer than thermocol.
OP may know...

Yes this is extruded poly styrene (XPS) which has more strength than dense EPP/EPS. I made it more strength by adding plywood/ CF spars using the foam spar cutter.

samayaraj · October 30, 2016, 04:11:06 PM

Quote from: saikat on October 30, 2016, 11:52:36 AM
good work - you make it seem deceptively easy.
you are quite advanced as I can see by your setup .

what are the spindles attached to the edge of your table ?
some sort of guide for your hot wire cutter ?

Thanks Saikat. Ya this spindles are used for gravity feed hot wire foam cutter. I removed the setup after cutting few of wings. I am trying to do composite wings especially to make DLGs.

samayaraj · October 30, 2016, 04:18:02 PM

This is few of my works.

Bigger flying wing is coverd with epoxy-fiberglass and plywood spar & smaller wing is just covered with cellophane tape with plywood spar.

tictoc21 · October 31, 2016, 10:49:37 PM

What is shape of cutter for that curve profile surface...

samayaraj · November 02, 2016, 07:19:14 AM

Its MH45 profile

K K Iyer · November 02, 2016, 08:33:08 PM

@samayaraj,
Sir,
You are an old member, who didn't post anything for 5 years after Oct 2011...

Saikat sir (an old hand) spotted your spindles. The time has come for you to post more stuff.

If you don't post your foam cutting videos, some of us may be left wondering whether we should cut a wing spanwise using an MH45 shaped nichrome wire, or chordwise with a straight wire and airfoil templates at root and rib...
Regards.

samayaraj · November 02, 2016, 10:52:17 PM

Dear Mr. KK Iyer,

Thanks for your reply. I was not active in RC during 2011 to 15 due to immense work pressure. Now I can contribute more time in RC activities.

Ya sure. Its my pleasure to share how to make GRAVITY FEED HOT WIRE cutting for wings. I will share it when I do next model.

This Tool cutter is only meant for cutting SPAR or HOLE for CF tube to reinforce foam wings/ any foam structures. I have posted wings just to show the use of this tool.