Weapons Case Hotwire Foam Cutting - 21 Pix (Diagram Added 6/20/12)

[Elwood_Blues]

That is weird that you keep frying transformers. If you got them from Radio Shack, I think they'll take them back. It also may be a good idea to put a fuse in the line regardless of how big of a transformer you use.

[finyllw]

I think the difference is the wire. I think you said you are using 24 gauge wire that has a resistance of about 1.6 ohms. The wire I am using is 20 gauge, it has exactly haly the resistance. It's putting too much of a load on the transformer even after using the dimmer.

I want a HOT wire, so I'll be oredering a BIG transformer on Monday. I think the idea of a fuse is a good one. I'd rather blow a fuse than another transformer.

[finyllw]

Well today I ordered a bigger transformer. 6 volts but 16 amps. Should be able to cook the foam right out of any hole. I ordered my stuff from Jacobs Online,
http://www.jacobs-online.biz/transformers.htm

I was dealing with Gary Jacobs, asking him all kinds of questions, and he suggested the one I ordered. It's actually a 12v 8 amp or a 6v 16 amp depending on how you wire it up. Gary was very helpful. If you are going to be building a foam cutter I would definitely check out his website. LOTS of really good info there to get you going in the right direction the first time. I should have my transformer Thursday or Friday, I'll be making foam cuts on Saturday if not sooner. I will post pics asap.

[Cali-Shooter]

Very nice DIY. Nice, clean job.

[VenturaMunitions.com]

Brilliant results, thanks for sharing this. Great weekend project.

[fouber]

Very clean. Thanks for sharing

[Dark Sky Solutions]

Got 2 ft of n-wire in the mail today thanks to footb82!!!

Great calgunner right there!!!!

[Szabi B]

A+ Job

[reloadyour9]

Great job on the cutting and the write up OP! Guys, one thing that needs to be mentioned as I did not see it in any of the pages.......be careful with the material you are buying!! I own a foam fabrication shop here in LA and do plenty of case work for Pelican as well as other companies (however mine is cut on a waterjet), and polyurethanes, or ethers, are highly flammable. Make sure you do one of two things, buy only flame retardant material, or do not stop while in the process of hot wiring the foam, or up in smoke it goes. Trust me, I almost burnt down my building several times when one of my automated hot wire tables motor went out while in the process of hot wiring.

Make sure you find out what material companies like Miller are selling you, and if you are unsure, PM me. The reps at Miller dont know much about the material, especially when it comes to the properties ( I supply them, they are just a distributor of my product).

Also, you can test the material by putting a lighter to it. It will burn, but if you remove the flame and it continues to burn, it is not flame retardant, so take extra precautions when hot wiring. If the fire goes out, you've got some good stuff (most likely 2# char ester. Ethers are no bueno, esters are FR.

Again OP, great job! Didn't mean to hijack, just want people to be aware. All it takes is somebody to interrupt while wiring, and the garage is toast.

Here is one I did, but using polyethylene, which is a closed cell material (water resistant)

[finyllw]

Thanks for the info "reloadyour9"

Ok fellas, update as promised.

I finally had time to get everything put together, I used a 6v 16A transformer, with a dimmer. I can get the wire red hot to melt off residual foam, then turn the heat down to cut. NO TRANSFORMER MELTDOWNS YET !!

I used the first aid kit steel (sealed) box, cut out the metal divider then cut the foam. I used 3 layers, 1/2" thick on the bottom, and top, and 3/4" in the middle. It all went relatively easy, had all the foam cut in less than an hour. I'm very happy with the results. The most important thing is PATIENCE !! Take your time with every step, trace your outline carefully, with the pen or pencil slightly tilted in so the foam will hold your ??? snugly in place. When cutting a straight line, I used a yardstick clamped to the frame. I was able to trim 1/8" using that method.

[Outsiders]

thanks for posting this!! I finished buildin mine and already cut a few and came out clean! Anybody in San Diego wants to have theirs cut, holla!

[finyllw]

"Outsiders" Thanks for the reminder,

Folks, I built this project mostly out of curiosity, and I did want to complete a couple of guncase projects. Somebody mentioned early on that it would be nice if someone would cut foam for them.

Well if you make a good template, and supply the foam, and if you trust me, I will cut the foam for you, or you can use my setup to cut your foam. I'm in NW OC, pm me and we'll see if we can work out the timing.

[P.Charm]

outsiders cuts

[ElDub1950]

another source of the Nichrome wire .. but this looks like a lifetime supply for $18
http://www.amazon.com/Nickel-Chromiu...ref=pd_cp_hi_3

[ElDub1950]

has anyone tried putting their pistol on a xerox machine to make a correct 1:1 profile pic?

Seems like the easy way to make a template to transfer to a piece of cardboard. Not sure if it will make the copy in exact size.

I don't have a xerox machine and somehow my local Copy Shop freaks out when I walk in and pull out my guns.

[finyllw]

The shadows that might come from the copy machine could throw you off. I'll try it later today and let you know.

[Elwood_Blues]

Nice cuts everyone! I'm glad to see that I inspired so many of you. Here is my latest little project I did for someone free of charge. I had scrap pieces of foam, one of which I had to cut on every side to make it fit Idea as suggested by 'finyllw'

[KalTac]

Flipping NICE !!!

Originally Posted by P.Charm

outsiders cuts

[P.Charm]

Originally Posted by KalTac

Flipping NICE !!!

Thanks. It was Ousiders and my first one. with his setup, it worked like a charm.

[Outsiders]

Originally Posted by P.Charm

Thanks. It was Ousiders and my first one. with his setup, it worked like a charm.

i'll post pics of my setup as soon as i find my cam

[Bunsen]

Looks like I have a weekend project to plan out.

[Outsiders]

here's my set up.

[Elwood_Blues]

Originally Posted by Outsiders

here's my set up.

That is awesome! Do you mind posting a picture of your cutter?

[P.Charm]

Originally Posted by Outsiders

here's my set up.

did you keep my template. I think i want to do mine like yours.

[finyllw]

Outsiders,

That is a way cool set up, uh, the case and the guns.

It would be cool to have a way to borrow templates. I have a stock 1911 template if anybody wants to borrow it. I'll be working on a M4 flat top template soon. I'm going to make it without anything on top, buttstock fully collapsed then make add on templates for scopes etc.

[Outsiders]

here's my cutter... used some scrap wood laying around and a platic sheet on top for a smooth top for the foam to glide. i also used a turnbuckle for tension. u could get it tighter than using a spring.

[Tackman11]

Well done

[KalTac]

That would be great!

Originally Posted by Outsiders

i'll post pics of my setup as soon as i find my cam

[KalTac]

Way cool

Originally Posted by Outsiders

here's my cutter... used some scrap wood laying around and a platic sheet on top for a smooth top for the foam to glide. i also used a turnbuckle for tension. u could get it tighter than using a spring.

[atc4usmc]

Tagged! Outsiders, PM coming your way soon Chief!

[Elwood_Blues]

I wish i had room for setup like Outsiders'. Might have to rearrange the garage a bit I love the turnbuckle idea.

[atc4usmc]

finyllw, can you scan and email your template for the 1911?

Anyone else have templates for pistols, 1911, H&K, S&W etc..?
Templates for AR's would be great too but Im not sure if we could devise away to scan them so we could distribute electronically..

[echoarms]

God I wish I had few enough guns to make this viable.

[finyllw]

atc4usmc,

I will try to get a 1911 and mag template copied and sent out ASAP.

echoarms,

In a previous post I offered my cutter for all to use. Contact me if you want/need to cut some foam.

[P.Charm]

Originally Posted by echoarms

God I wish I had few enough guns to make this viable.

my pelican only has one.

[5150bronco]

Great write up. Thanks.

Has anybody thought of using proton foam cutter or hot knife?

I am looking to start making stuff now. Thanks.

[supersonic]

PM sent. I have a brand new / never used Proxxon Table for sale in the Marketplace for $75 (IIRC).

-SS

[shortyforty]

Awesome job! I always wondered how this was done. Thanks for posting.

[Dan FS71]

Excellant.

[budah1999]

this process is called hot wire cutting they use it alot in homebuilt aircraft but becareful when selecting your foam not all can be cut with this method.you can purchase most of the items for buliding the cutter at AIRCRAFT SPRUCE in Chino CA i think they sell foam too i would check your local upholstry shops. good job on the case bro!