Hi All,

Advice wanted on the above basically...
I've read an "Instructable on a hot-wire cutter that was quite informative, but I wanted to make one that was able to cut foam into round bar.

I would happily buy some, but I haven't been able to find any suitable stuff - for eg Scaffolding protection, hot/cold water pipe protection etc. almost all of it comes with a slit in it, which tends to force it to curve or twist.

Obviously if I could cut my own with the hot wire cutter, then I could also control the exact shape. For eg, if I wanted a round shape to morph into an elliptical shape, then that would be possible etc...

So, has anyone ever done it?

Can anyone suggest the best (lowest cost) items to power it etc. Can I use a car battery, can I use a Halfords battery charger etc?
I know nothing (zero, nada, zilch, diddly squat) re electronics and the way that electric conducts itself in wave patterns for DC & AC etc. So I am really open to as much constructive advice as you "guys" can produce!

I always wanted to have a go at the electrolysis, but never had the point! Do people that have done that think that this is similar? If so, do you have any advice that might be worth it etc?

OK - Thanks in advance for all your suggestions and advice...
Cheers,
Steve.

I use one I made from a length of 4x2 and uses nichrome wire and a battery charger.

Be warned that the wire gets longer with heat, and the tensioning system needs to be quickly adjusted.

Cheers,
Nev.

Hi Steve , we have various line benders and wire cutters at work, 'cos they are used by kids they are alll professionally made, risk assessed etc however the firm that makes them very helpfully publishes all manuals on the website so that may give you some useful info

http://www.crclarke.co.uk/products.html

manual is here:

http://www.crclarke.co.uk/products/PDF/inst/180instEN.pdf

Hindleys sell spare wires etc see

http://www.hindleys.com/machine-and-power-tools/plastic-forming-machines/hot-wire-cutters/


Cutting foam is not a very precise science like extruding alu or plastic - the slightest wobble and there's a chunk missing from your work .
We have one of the triform 180 machines which bends as well as cuts, with a foot operated pedal going spare but I don't know exactly what it is worth, I guess it depends how much you need to cut , if you were closer you would be welcome to come and have a go even though we are on holiday until September. You might find someone close by who has similar gear

atb
Mike

I have a home made one that just runs off a car battery, simple wooden bow bent like a kids bow and arrow. I use mine to cave rc plane parts. Lessons learned were -

1) connect furthest away first or you risk the wire glowing and either melting or stretching too much, wear safety specs as it may whip back

2) don't cut free hand if you care about what you cut otherwise it will be hilariously inaccurate, the wire flex's alot

3) don't push the wire though, let it find it's own speed

4) always use templates for the wire to follow, thin plywood worked best, thick card if if the item is very thin

5) wire should not really be glowing at all but just be smoking if touched against the foam

6) do it outside, the fumes are terrible and not good for you one but, blue or pink foam are the worst

7) harder than it looks but easy to learn, expect to make a heap of rubbish at first!

B&Q Warehouse sell/sold pipe insulation without the slit,it is/was a lot softer than the usual stuff and sold in rolls.
I haven't looked for it for a while, so don't know if they still sell it.

A bit late, but you might find this YouTube video useful...

Hot-wire cutter