URETHANE FOAM SHAPING
.....BASIC TOOLS: Sharp butcher knife, sanding block, surfoam file,
wire brush and blocks/scraps of urethane. Use a dust mask. Hack away,
have fun.
HOT WIRE CUTTING STYROFOAM
.....Hot wire tool has a length of 56".
.....Wire must be tight. The adjustable voltage control is best, but
the job can be done with 212-volt, 6-amp battery chargers or 12-volt
car batteries. Foam block must be well supported and weighted.
Templates must be nailed on tight. First cut the basic block to size;
this determines the planform size and shape. Level the template level
lines; this determines correct twist. Set hot wire temperature for
about 1" travel through the foam in about 4 to 6 seconds with light
pressure. Do the actual cutting at about 1" every 6-7 seconds (8-10
sec. around the leading edge). Practice on scraps first.
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