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I've been using that particular brand of foam saw for several years now.  It's been quite reliable and it isn't nearly as expensive as a Bosch.  But, and I could be wrong about this, I think the both the blades on a Bosch move, on the one pictured only one moves. 

I've found that you need to be good about cleaning the blades regularly if you cut through a lot of glued foam.  I am not allowed to use silicone spray at work, but in the past I've used it routinely and it really makes a lot of the cutting a good deal easier, esp. on tight radii.  It's very loud; I like to use hearing protection when I have a lot of cutting to do... boss laughs at me. 

(I need to buy a saw for myself and that's the one I'll probably buy).

[have]

The thought of flames around the bottom of it cracked me right up, Bobby.  You have to do that!

Seems to me that was an option and could be ordered on other models, too, but I could be wrong about that.  I didn't even know what it was for when my machine was delivered... found out afterwards that you can also get a push button feature that will adjust the foot at the touch of button (missed that boat, lol).  I think the mechanic told me that could be added to my machine "after market", but I could be wrong about that, too!

Anyway, I was wondering if you'd had any luck getting the adjust "dialed in" and how well it's worked out working on loftier goods.  I was doing something at work the other day that required the Consew 255RB2 to step up and then down over a lot of thickness and I instinctively reached for the dial... but no!  What a handy little feature!

Or maybe put a the zipper on one of the long sides?

I had to stuff a couple of "hinged" cushions for a chaise lounges yesterday.  The zippers had to go just on either side of the hinge and it was definitely "no fat lady's dream" to get the longer piece of of foam (wrapped in batting, too) in and attractively arranged.  It's been wicked hot here and I worked a up pretty good sweat doing it. 

Grebo, when you use the vacuum cleaner, what do you used to wrap the foam so it will compress? how to do remove it after the foam is in place?

Excellent point, June!

But all the IRS has to do is pull the records of the 1099d "employeee".  If the "employee" hasn't paid their taxes (as they're required!) then the jig is up.  But if the 1099d produces the records, there's no problem. 
 

I have been sewing professionally for over 30 yrs. now.  I hail from the ranks of garment work... several years in a strict production setting (hence my exposure and comfort level with varied types of machinery), and before that I worked for a tailor.  I can measure your body, draft a pattern and make you a sport coat and I can work on your fur coat, too.  I've always had a variety of industrial machinery in my own shop here at home (it's a disease with me).  I cut my teeth on drapery work by making all the draperies in our home, then moving on to smaller outside jobs.  I did the same thing with cushion work and slipcovers.   I fell into marine and awning work 18 yrs. ago on a referral from a mechanic friend of mine... I wasn't afraid of commercial sewing machines and the guy needed someone to stitch.  I was it. 

I've never pulled any punches with my prior employers about the fact that I work from home part time.  Technically, there is some overlap with work I do "in the shop" and work I do "at home"; but since I've worked from home longer than I've been employed "in the shop" and I pointedly avoid awning and marine work at home I feel no conflict of interest.  I suspect, though, that that's at the crux of the issue for the overbearing "clamp down" and the refusal to allow me a inch of creativity or participation aside from guiding fabric under the needle.

But, you can't 1099 someone if you can't write up a comprehensive work order with adequate specifications (the way they do in factories when they do production runs). 

Many, many moons ago when I worked in a very high end tailoring shop a customer asked about a repair to a 3 corner tear in a very expensive suit.  We gave him the usual options  which included sending the garment out for reweaving ($$). 

I still quote the advice given him for the less expensive option:  "we can fix it but we can't make it disappear".  That pretty much sums it up. 

Why would there be? whatever you change via the dial you can always change right back, can't you?  The dial is calibrated, you have the manual and there is no way you can screw this up. 

It's a lift dial, not a a neutron bomb!  (feel better now?)

If you are running the stitch length at 9mm and it's still too short the answer is to adjust the step of the feet. 

Here's what I'd do:
Set the stitch length dial at your usual length.  ( I like 5-6 mm, personally). 
Then, incrementally begin adjusting the step and track what the net effect is on your sample. 

As I understand it (I'm new to this feature, too!), you should be able to adjust the step via the dial so that it accomodates the the thickness of the material you're stitching and still delivers the desired, pre-set stitch lenth on the dial. 

When you think about about it, you are simply commanding the feet to step higher (over the loft of the work) to deliver the same stitch length.  Don't be afraid to use your machine to its fullest capabilities!

I haven't made a dodger in 11 years.  And they were fun to make, too!  I miss that part it.  What a great link and what fun to see how creative and precise marine canvas can be!  (needed to see that after a crummy day at work, but now it only underscores what pit and backwater I work in, lol). 

My query about "1099ing me" was met with outright refusal this morning.  What a surprise. 

Time "To get busy livin' or get busy dyin'", I guess.   This in between crap is basically nowhere'sville. 

Are you running the stitch length as long as it will go?  I know my Juki 1541 has a dial for the stitch length and it allows a really long stitch.  Try that first and see if you can get the sort of length you want to see. 

But, my guess is that adjusting the step of the inner foot is going to be the answer to your question.  If the foot is able to step higher it will be able to better cope with the overall loft of the 1/2" sew foam you're using. 

Do you have a manual with the machine? why are you afraid/hesitant "to go down that road"?  Think about it, you've just purchased a very practically engineered machine, designed for the sort of work you wish to do and you aren't willing to fiddle around with it and find out what it can do to make your job easier!

It's a machine.  Designed and engineered by people.  Don't let it freak you out. 

[lobbyists]

I don't hate oil comapanies.  They provide something all of us need.  And, as businesses, they have every right to turn a profit. 

I don't hate polititians.  They are there to represent the wishes and needs of their constituents.  Evaluted by that, we have precisely the elected body we vote in... since statistically only older and more wealthy citizens tend to vote with any regularlity... representation of their needs/wishes is well represented. 

I have a big problem with lobbyists, however.  When there is no control over when and how the ranks of the vocal and well financed lobbyists find their way into the offices of our duly elected officials I see a big problem... .  And, IMO, what we are now witnessing in the Gulf of Mexico at the hands of BP is entirely traceable to the doorstep of lobbyists and beneficial governmental appointments to assorted boards charged to "oversee" regulation.   Those boards and agencies are stocked with "plants" from huge, muliti-national corporations backed by huge bankrolls.  Those appointees don't represent the fishermen, motel owners, take-out food restauranteurs....  .  Maybe this horrible, entirely preventable ecological disaster will finally wake up the country about the way "business is done" in "the land of the free and home of the brave. 

We are  supposed to be a "free enterprise" Capitalist enonomy? give me a break.  The "free" part was squelched decades ago, my friends.  It ain't, "free"... it's totally and completely in the hands of major corporations... and those wealthy and regular voters (who receive dividends from those major corporations). 

When Bubba in Redneckland and some spoiled Soccer Mom in Suburbia decides that he (or she) doesn't really need 4WD in Florida/wherever they "call" school for 3" of snow and begin to lobby for an electric commuter "truck" or actually require Jr. to use the publically funded schoolbus we'll turn the corner.  Until that time we'll laugh at Europe, pound our fists on our chests and repeat over an over again how we are the greatest nation on the face of the earth. 

I don't disagree with the sentiment.  But I have huge problem with the how and the why of the sentiment.  We, as a nation need a very serious "grow up pill", and I've been tirelessly writing to my elected officials about the necessity since 1985. 

Boss is a good person, Sofa..  Just doesn't have much in the way of a clue about the importance of creativity and allowing the worker bees a chance to quarterback their own projects.  For someone like me, it's downright irksome, for most... not a problem, at all.  ;)

Not sure how to move from a very comfortable job  to the far riskier provence of "self -employment"... would like to segue with sub-contacting (bring on the 1099) but am not sure that would be welcomed.  Boss is already suspicious about my pursuit of slipcover work and "outside" cushion work. 

I regularly peruse E-Bay and Craigslist for sewing related offerings.  But I've never actually purchased anything from either. 

I call my ace sewing machine mechanic for my attachment needs.  I'm cool with the extra $; he's a local businessman who faces the same constraints and overhead we all do.  I know that when I buy from him he'll stand behind whatever he sells me.  He's candidly told me that he can't beat a price and that I should buy from whomever. 

Kind of makes you wonder when vendors "to the trade" start showing up on E-Bay... what exactly are they selling there... seconds, close-outs? are they making the same deals to their "to the trade" customers? by prior notice, with any exclusivity? 

I nothing to offer, sorry, Doyle. 

But I do have an iron frame chair with no fewer than 45 buttons accenting diamond tufting on the back, seat, and inside arms!  It really is a fabulous piece, the workmanship is "old school".  All the stitching is hand done, and the entire outline of the piece is done in neatly folded "ruching".  Clearly, it will not be my first project in this style...

::)