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General Upholstery Questions and Comments => General Discussion => Topic started by: Vtool on October 01, 2011, 09:08:31 am

Title: hot wire foam cutters
Post by: Vtool on October 01, 2011, 09:08:31 am
Does anyone have any experience with using hot wire foam cutters? my wife's father designed a hot wire cutter for foam insulation. he made alot of money off his design. it made it possible to use thinner layers for industrial buildings. I figure use his experience and maybe design a portable unit for auto and boat foam repair and replacement. also this gives the two of us some common ground to relate to each other.                                                                 David
Title: Re: hot wire foam cutters
Post by: kodydog on October 01, 2011, 09:52:37 am
Just thinking out loud here. Seems like the heat would melt the polyurethane foam causing it to form a "skin". I'm wondering what the appearance would be when stuffing a 4" foam into a 3-1/2" casing. Over time, would it cause the skin to wrinkle? Or would it give the border a stiff feel?

The next question is would it be faster or more economical than an electric foam cutter? A Bosch foam cutter is between $300 and $350. Can you build, market and sell for less than that.

Interesting concept. We love creative ideas in this forum.

All you can do is try and see. Let us know.

Title: Re: hot wire foam cutters
Post by: scottymc on October 01, 2011, 02:12:07 pm
A guy I worked for in the 80's made one, he used it for cutting poly styrene foam to shape surfboards. It was pretty crud, basically a wooden bow with a fine wire and positive and negative connected to each end and plugged straight into 240v, scary stuff. :o   
Title: Re: hot wire foam cutters
Post by: Bob T on October 02, 2011, 08:21:41 am
I made my own hotwire foam cutter following instructions I found doing a Google search for "How to make Hotwire Foam".  It really was quite easy using a standard 110v transformer for 12v track lights and a dimmer.  These are readily available at most lighting stores. The tough part is getting the right wattage transformer.  If you go too small, the wire won't get hot enough and will cut very slowly.  I think I used a 250 watt transformer but should of used a 500 watt transformer. With the 250 watt transformer, it cuts slow because the wire doesn't get hot enough even on max heat.  I've never got it hot enough to cause the wire to become weak.  The Dimmer controls how much of that wattage goes thru the hot wire itself.  You can also use a model train transformer, but I have no knowledge of what size works.  I think I wound up spending about $60 for the hot wire, the PVC plastic pipe bow, the transformer, the dimmer, and the misc. electrical cords.  Took about 1.5 hours to make it.

I know you can find instructions on making the hot wire  here:
http://www.garageofevilnetwork.com/   but the website is a nightmare to navigate and find the instructions to build the power unit. You have to join first, then when you get into the site, click on "HOW TO" at the top and when it comes up scroll about half way down the page to "PETES How-To!,Hot-Wire Foam Cutter, Core, variable power, Power Supply, for $20"

I use mine to cut styrofoam to build my own windsurfers.  It works fine with styrofoam but does not work so well with urethane foam.  If you try to use it to cut urethane foam, do it outdoors because the fumes are said to be noxious.
Title: Re: hot wire foam cutters
Post by: Vtool on October 02, 2011, 06:37:08 pm
after reading the responses. I will get a bosch foam cutter.  thanks for the heads up on toxic fumes.
                                                       David
Title: Re: hot wire foam cutters
Post by: Mojo on October 03, 2011, 05:15:08 am
David:

If you do a search of this site you will find a thread started by June on a vendor who had great prices on the Bosch foam saw.

Myself I cut such little foam that I use an electric turkey carving knife. It works good you just have to spray the blades with silicone spray now and then. I would love a Bosch saw but just cannot justify the expense when I cut very little foam every year.

Chris
Title: Re: hot wire foam cutters
Post by: JuneC on October 03, 2011, 06:07:15 am
The Bosch works great!  I got a new one, but occasionally one comes up on EBay for a very good price.  I put in bids on several and always lost  :(

One thing surprised me though, it's a very heavy tool.  I get fatigued when doing a lot of foam cutting like I have been lately.  I suppose it's well built, though, lots of metal.  Another thing.  It has a lot of torque when starting.  Definitely start the blades before making contact with the foam.  And... I'd love it if the body was just a little smaller.  My hand can barely fit around it.  I can only press the trigger with the very tips of my 2 middle fingers.  This probably contributes to my fatigue.

June
Title: Re: hot wire foam cutters
Post by: Judy_Boat on October 03, 2011, 07:55:43 am
Hi all,
I have built the hot wire cutter and tried the upholstery foam on it.
Do not bother for this use. Stick to styrofoam with them.
Basically, the foam cut so slowly, it dragged hard enough on the wire to force the wire to curve, causing a wobbly cut. It did not cause a skin to form.

On a different note with holding the Bosch cutter for a long time. I have clamped the stabilizing foot to my table  top and then just shoved the foam past the blade. I find it works nicer when shaving small sections off.
Title: Re: hot wire foam cutters
Post by: fragged8 on October 03, 2011, 04:00:49 pm
I have a foam saw from this site, it works well and very good price

the blades were like $9 but the bosch ones in the Uk are about $150

support Ken (site owner) and check his shop out
no he isn't paying me heheh

http://www.get-up-and-go.com/mm5/merchant.mvc?Store_Code=G&Screen=PROD&Category_Code=TS&Product_Code=foam-saw
Title: Re: hot wire foam cutters
Post by: Rich on October 03, 2011, 07:15:22 pm
If you already have a band saw, you can cut foam with that too. Actually, I found that out here on this site and was amazed at how well it cuts. Increased the usefulness of that machine considerably for me!
Rich
Title: Re: hot wire foam cutters
Post by: gene on October 03, 2011, 07:45:15 pm
Hey Rich,

I have been looking at a band saw to cut foam. The cost of foam is getting higher and higher and I have been thinking of cutting and gluing scraps together more than I have in the past.

I used an electric turkey knife today to cut 5" foam into strips that are 2 1/2" thick so I could glue them up and have a 2 1/2" cushion insert. It worked well but the turkey knife was working rather hard.

Do you have a special set up for the band saw, such as a large table to feed the foam, or does it work well just as it is?

Thanks,

gene

Title: Re: hot wire foam cutters
Post by: kodydog on October 03, 2011, 07:51:11 pm
I worked for a guy in Gainesville Fl who made a foam slicer. He took a band saw and mounted it sideways on a frame.

Beneath it he built a platform out of plywood and mounted small wheels to it. This gave it forward and backward motion to feed the foam into the blade.

The platform was supported by small hydraulic jacks for up and down motion.

He could take up to a 36" wide piece of foam and slice it any thickness you want.
Title: Re: hot wire foam cutters
Post by: Vtool on October 04, 2011, 04:11:06 am
we use a band saw at work to cut foam. after looking at price of complete bosch foam saw. thats insane. I could get a nice bandsaw for a cheaper price. only advantage of bosch foam saw. small size compared to bandsaw. also bandsaw is multi use over bosch. I discussed this same subject with fellow co-worker yesterday. thanks for input everyone. saved me from toxic fumes of hot wire.
                                                                                    David
Title: Re: hot wire foam cutters
Post by: Peppy on October 04, 2011, 04:30:50 am
Wow June, you must have itty bitty hands! I had to go look at my saw to see if we were talking about the same bosch. Can't you lock the saw on? On mine when it's running you can slide the switch back and it will stay running.

In my mind the other advantage to a foam saw over a band saw is the foam saw ONLY cuts foam and so does it very well and with great agility. I can cut a wedgie 6" to 0" on a six foot piece with nothing more than a line on the foam. A band saw is very good to have, but it doesn't replace a foam saw of some kind.
Title: Re: hot wire foam cutters
Post by: JuneC on October 04, 2011, 06:28:48 am
I don't think I could have done this with a band saw.  I'm doing lots of carving on this project.  Luckily, DriFast 70 carves really easily since it's so firm. 

(https://forum.upholster.com/proxy.php?request=http%3A%2F%2Fi40.photobucket.com%2Falbums%2Fe225%2Fjune-c%2Fth_P1010115.jpg&hash=998fc55f07dbcbd228a966454006859d) (http://s40.photobucket.com/albums/e225/june-c/P1010115.jpg)

(https://forum.upholster.com/proxy.php?request=http%3A%2F%2Fi40.photobucket.com%2Falbums%2Fe225%2Fjune-c%2Fth_P1010113.jpg&hash=75e095b40a40e359f5e5bea31497e80c) (http://s40.photobucket.com/albums/e225/june-c/P1010113.jpg)

My saw has the switch lock which helps, but it takes two hands to get it on, then off.  I'm just getting used to handling the thing. 

June
Title: Re: hot wire foam cutters
Post by: Vtool on October 04, 2011, 05:00:14 pm
I just noticed the cutters listed above. don,t need the band saw . thanks for the video of operation of cutter. better price than bosch. if anything I learned from this post. I appreciate people warning of toxic fumes. Glue fumes are the worst of my job. no need for added lung irriatation. thanks
                                                                      David
Title: Re: hot wire foam cutters
Post by: Rich on October 04, 2011, 07:10:58 pm
Gene, I made a plywood platform topped with formica to extend the table on all sides. It's approx 30"x40". Also, I added an extension kit to the arm which increased the throat capacity to 12". It now uses 105" blades.

Kodydog, I like that idea!

JuneC, I think you'd be surprised how much you actually can do with a band saw. The foam in your pix could be.

I still use the Bosch saw when necessary, but for smooth, right on the line cuts, especially on thick foam and when I want a perfect 90 degree cut (or any other angle), I use the band saw
Title: Re: hot wire foam cutters
Post by: BigJohn on October 05, 2011, 04:25:16 am
June:
     Your not just an upholsterer but an artist as well! That was some pretty fancy carving!

                                      Big John
Title: Re: hot wire foam cutters
Post by: fragged8 on October 06, 2011, 04:08:17 am
June, i really need to see that job progressing :-) looks like a nightmare
of curves to cover

Rich
Title: Re: hot wire foam cutters
Post by: gene on October 06, 2011, 05:14:59 am
Thank you Rich, and k dog, and others for your replys.

I was not aware of extensions for band saws. The throat depth was one area that I was concerned with.

Working with interior designers my competition is usually new furniture. Does the homeowner want to reupholster or buy new?

With my labor, the fabric, the designers' mark up, the foam, the pick up and delivery, the more scraps of foam I can use the better. And with the adhesives today the pieces of foam will not be falling apart.
Title: Re: hot wire foam cutters
Post by: kodydog on October 06, 2011, 06:37:42 am
I do the same thing Gene. If I have a 26" wide piece of foam and need 28" I'll add 2" to it. I think its just as strong as unpieced foam and I've never had a problem with it coming apart. I've never had any complaints but I always wondered what the customer would think if they ever saw that it was pieced. Of course on a tight seat or back they would never see it. 
Title: Re: hot wire foam cutters
Post by: fragged8 on October 06, 2011, 11:21:59 am
it's all come full circle again

I remember taking covers off of old seat cushions
and the foam was made up of pieces glued together.

Now we are going back to it.  :-)
Title: Re: hot wire foam cutters
Post by: JuneC on October 06, 2011, 06:55:46 pm
Yep, the curves are giving me fits in design, but I think I have a plan.

And...  y'all keep talking about foam going up.  My supplier hasn't increased the price of foam since 2009 and with the current BIG drop in oil prices, I expect it'll not go up anytime real soon.  And no, the quality has not dropped.  In fact, I think it's better than ever.

June
Title: Re: hot wire foam cutters
Post by: forsailbyowner on October 09, 2011, 09:35:58 am

Check these guys out for foam. They advertise they will beat anyones price for same by 8-10 %.
not affiliated



http://www.foambymail.com/SFNT.html
Title: Re: hot wire foam cutters
Post by: gene on October 09, 2011, 02:08:13 pm
Mr. Forsailbyowner,

Your info says you are in Tampa, FL. If you make sails for boats, you've got a great handle.

Have you used this foam supplier before? If so, how was it?

Has anyone else used Foam Factory?

I'm about 300 miles away from their Michigan location. I have a foam supplier right here in town, about 20 minutes from me. The Michigan link shows prices that are a bit less than what I can get here in town for very close to the same specs. And with their free shipping on orders over $75.00, they look like a pretty good deal when I need a lot of foam and don't need foam right away.

I'm not affiliated with them either, but if they want to cut me a check for touting their name I will gladly tout away. But only after I order from them first and they are what they say they are.

gene
Title: Re: hot wire foam cutters
Post by: sofadoc on October 09, 2011, 03:03:10 pm
I got a bunch of sample foam pieces from The Foam Factory. The samples and the prices were no incentive for me to buy from them, instead of locally.
I get free foam delivery monthly with no minimum order.
Quote from: JuneC on October 06, 2011, 06:55:46 pm
And...  y'all keep talking about foam going up.  My supplier hasn't increased the price of foam since 2009 and with the current BIG drop in oil prices, I expect it'll not go up anytime real soon.

My supplier recently went down 20 bucks on a 6X24X108 sheet of foam.
But don't expect falling oil prices to have a direct impact on foam prices.
Katrina destroyed one of only 2 refineries that produce the crude oil by-product that goes into foam. Unless they build another refinery, foam prices will be effected by short supplies of that by-product.
Title: Re: hot wire foam cutters
Post by: JuneC on October 09, 2011, 04:20:58 pm
Quote from: forsailbyowner on October 09, 2011, 09:35:58 am

Check these guys out for foam. They advertise they will beat anyones price for same by 8-10 %.
not affiliated

http://www.foambymail.com/SFNT.html


Well, they gotta go a bit to beat the price I get on Dri-Fast.  Using their estimating on-line tool, a sheet of dri-fast in the size I get it - 52 x 118 x 2 - theirs is $217.32.  I just bought 2 sheets that size for $118 each.  Same price for dri-fast 30, 50 or 70.  I kinda doubt they'd knock off $100 right off the bat.  And mine's not glued - that's a standard size sheet.  I find big sheets yield less waste if you plan your cuts.

June