Parts
Here is a simple, inexpensive, safe foam cutter you can make and use that really works. By Lee Aston
LINKS TO BUY TRANSFORMERS, WIRE AND EPP FOAM
The power supply kit sold by Aircraft Spruce works well. It is recommended by Burt Rutan for cutting passenger-carrying, full-sized homebuilt aircraft. The parts from this kit can be used in the power supply I use. It does require assembly and the purchasing of a common household outlet and a GFI outlet. If you don’t understand the plans, get help building the cutter from someone who does:
http://www.aircraftspruce.com/catalog/cmpages/hotwirekit.php
If you want a transformer with a little more power, buy this one at All Electronics and get the dimmer, GFI and the wall outlet at your local hardware store. This transformer has a 24 volt 5 amp rating and is the same size at the 3 amp transformer at Aircraft Spruce.
http://www.allelectronics.com/cgi-bin/category.cgi?category=search&item=TX-245&type=store
Heating this wire is the sole purpose of this power supply. If you look at the link above Aircraft spruce also has some cutting wire. The wire they offer is 0.032 and 0.041 gauge. The wire cuts well but draws higher amperage than the transformer is rated for on a 40 inch bow. I have had it draw between 7-8 amps.
There are many kinds of wire and everyone has their favorite. My favorite is single strand chrome nickel fishing leader sold by Mason Tackle Company. Fishing leader is a good cutting wire because it is small and strong. I have tried multi strand wire and had it cut well, but it does not slide over the jigs as well and tends to draw more amps than the transformer is rated for.
Here is a source for the chrome nickel fishing leader. Thorne Bros sells the fishing leader in many sizes including 0.022, 0.020, and 0.018 gauges. The 0.020 is a good wire to start with if you are making a 40" bow. It comes in a 25 foot package or a ¼ lb roll.
http://www.thornebros.com/muskie/terminal_tackle/leader_components/lc_mason.html
Here is a source for EPP foam. I usually order sheets of the 2" x 24" x 36". This is enough foam for 3 Wild Wings if you don’t make any mistakes
http://flyingfoam.com/foamsheet.html
I hope this information will be helpful. I am a hobbyist not an electrician or an engineer. What I am going to tell you is the way I have made my foam cutter work for me. There are many other good ideas out there and I encourage you to seek out other ideas and methods to make your foam cuts as safe and precise as you can.
