The Hercules® Deluxe Hot Wire Table #8500 DHWT is a specialized cutting device designed for precise and clean cutting of low-density foam, polystyrene, and Styrofoam. It is intended for use in dry environments and is a Class II protection device.
Function Description:
The primary function of the Hercules® Deluxe Hot Wire Table is to cut various foam materials using a heated wire. The device allows for several cutting types, including straight cuts, miter cuts, parallel cuts, cylindrical cuts, and conical cuts, enabling users to create intricate shapes and designs. The cutting process involves moving the workpiece through a heated wire, which melts the material to create a clean edge. The device features an adjustable temperature level, allowing users to optimize the cutting temperature based on the material and desired cut complexity. A foot pedal controller is included for intermittent cutting, which is particularly useful for complex shapes, circle, and conical cutting, providing hands-free operation to manipulate the workpiece.
Important Technical Specifications:
- Voltage: Primary 115 Volt, 60Hz; Secondary max. 10.5 Volt, 60Hz.
- Power Rating: Max. 25W.
- Secondary Current: Max. 1.7 A.
- Dimensions of Work Surface: 14 ½" x 10 ¼" (370 x 260 mm).
- Max. Cutting Height: 5 ½" (140 mm).
- Throat: 13 ¾" (350 mm).
- Weight: 8lb (3.6kg).
- Cutting Wire: Φ0.18mm, length 5m (Replacement wire #6555).
Usage Features:
The Hercules® Deluxe Hot Wire Table offers a range of features to facilitate various cutting tasks:
- Foot Pedal Control/Switch (1): This optional feature allows for hands-free operation, enabling intermittent heating of the cutting wire. It is particularly useful for intricate cuts, circles, and conical shapes, where both hands are needed to guide the workpiece. The power switch (17) must be set to the "FOOT PEDAL Mode" (=) for the foot pedal (22) to function.
- Temperature Level Adjustment Knob (3): This knob controls the heat of the cutting wire. A guide table on the front of the device helps in selecting the appropriate temperature based on material thickness and desired cut. Higher temperatures are suitable for straightforward cuts, while lower temperatures are recommended for complicated shapes to prevent untidy edges and material burning.
- Standby LED (4): Indicates when the device is powered on.
- Knurled Screw for Clamping the Cutting Wire (5, 15): Used to secure the cutting wire in place, ensuring proper tension.
- Circle Cutting Attachment (6, 03): This attachment can be fitted onto the extension rail (16, 04) to facilitate accurate cutting of cylinders and cones.
- Overarm (7, 02): The upper support structure that holds the cutting wire and spool carrier.
- Wire Spool (9, 07): Contains the cutting wire (replacement wire #6555).
- Spool Carrier (11): Holds the wire spool and allows for tension adjustment by sliding it along the overarm.
- Guide Slot (12): Guides the angle/miter gauge and extension rail.
- Guide Wire (13): The actual cutting wire.
- Lower Wire Guide (14): Helps to position and secure the lower end of the cutting wire.
- Slot for Angle Stop (15): Used to fix the angle/miter gauge.
- Extension Rail (16, 04): Provides an extended surface for guiding workpieces and attaching accessories like the circle cutting attachment.
- Angle/Miter Gauge (17, 13): An adjustable guide for making miter and parallel cuts. It can be fixed at various angles using the miter angle adjustment screw (18) and positioned along the rail using the rail adjustment screw (19) and slide adjustment screw (20).
Cutting Types:
- Miter Cutting: Can be achieved by adjusting the spool carrier on the overarm (loosening screws 1 and 2 in Fig. 3) or by using the adjustable angle/miter gauge (17). Adjusting the spool carrier changes the length of the heated wire, requiring temperature recalibration.
- Parallel Cutting: The angle/miter gauge can be fixed in the slot using screw 3 (Fig. 5) to guide the workpiece parallel to the cutting wire.
- Small Sections of Long Profiles: For cutting small sections, a waste piece (1 in Fig. 6) can be placed between the rail and the workpiece, allowing the cutting wire to cut into the waste piece and ensure clean edges on the main workpiece.
- Cylindrical and Conical Cutting: The circle cutting attachment (2 in Fig. 7) can be mounted on the extension rail (2 in Fig. 5) to cut out cylinders or cones. The foot pedal switch (1 in Fig. 7 & 8) allows for hands-free control, enabling the user to rotate the workpiece accurately.
Important Hints for Usage:
- When cutting double miters (e.g., for a roof), do not remove the first cut-off part; use it as an underlay for the second cut to maintain accuracy.
- The cutting wire tends to be hotter at the exit side of the workpiece, which can cause surface melting. Blowing on the wire can help cool it down and prevent this.
- If the cutting wire breaks, it usually occurs above the guide bushing. Insert the wire a few inches further into the lower wire guide and fasten it again at regular intervals to prevent repeated breakage.
- Always move the workpiece through the wire with light pressure and even speed. Excessive pressure, especially with complicated shapes, can bend the wire.
- The wire may extend slightly after the first heating. Stretch it gently during the initial heating and re-tension it; it will then retain its length.
Maintenance Features:
Proper maintenance is crucial for the longevity and performance of the Hercules® Deluxe Hot Wire Table:
- Safety First: Always ensure the machine is UNPLUGGED FROM THE POWER SOURCE before performing any adjustments, maintenance, cleaning, measurements, or repairs.
- Cleaning the Machine: Regularly clean the wire and the bushing around the Lower Wire Guide to prevent the build-up of polystyrene residue, which can affect cutting performance.
- Wire Tension Check: Before each use, check and adjust the wire tension. A loose wire can lead to uneven cuts, burn material, or even cause injury.
- Work Surface Cleanliness: Keep the tabletop, extension rail, and guide slots free of any build-up or debris to ensure accurate cuts and prevent errors with your material.
- General Cleaning: The device should be cleaned with a soft cloth or brush after each use. Mild soap or other suitable cleaning agents can be used. Avoid solvents or cleaning agents containing alcohol (e.g., petrol, cleaning alcohols), as these can damage the plastic casings and markings on the device.
- Ventilation: Provide good ventilation when using the device to disperse fumes or gases created during cutting.
- Material Safety: Always observe the material suppliers' safety instructions when cutting.
- Burn Risk: The cutting wire is hot; exercise caution to avoid skin burns.
- Combustible Materials: DO NOT use the device near curtains or other combustible materials.
- Supervision: DO NOT leave the device unattended when it is switched on.
- Wire Replacement: Only use the supplied cutting wire or genuine Hercules® #8500 DHWT replacement wire (#6555). Using other wires can overload the transformer and damage the unit.
- Power Off: Always switch off the device after use.
The Hercules® Deluxe Hot Wire Table is a versatile and essential tool for hobbyists, model makers, and professionals working with foam materials, offering precision and ease of use with appropriate safety and maintenance practices.
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