Here is a simple, inexpensive, safe foam cutter you can make and use that really works. By Lee Aston

With a little practice, you will be able to cut excellent quality cores. I have also included plans for the power supply and accessories that can make your cuts look like they were cut by a CNC.

On January 27th 2005, with two of these cutters cutting wings and one cutting the trailing edge, we cut 53 EPP "Wild Wings" or 106 EPP halves in less than 2 hours with only 2 single panel rejects which were both caused by operator error and not equipment error.

I am including free plans for my EPP "Wild Wing" which is one of the most enjoyable planes I've ever flown in my 33 years of flying. The construction of the "Wild Wing" is described through the text as each technique and tool is discussed. I hope you like it. It will make a good project to try out your new cutter. The "Wild Wing" will surprise you.

Do not be afraid of the cutter, but do not hurt yourself by being careless. No matter how many instructions are given, nothing can replace your common sense and safety-minded use of this tool. I have cut for 22 years and have never been shocked, but I have been burned by a drip of hot plastic off of the cutting wire.

Think of foam cutting in the same way as you think of welding. If you are welding you take safety precautions and have safety gear and no one gets hurt. If you have questions, get on the internet or talk to an expert and find some answers.

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.