Thread: Project $ 3 K Is Underway

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Don,
I know it's messy working with the foam the way we instructed you, but there is a method to shaping the foam that is entirely dust free and gives it a final finish.
It's called the hot wire and bow.
The reason I didn't reccomend this off the bat is because you'd have to do searching for the components (all readily available, and inexpensive) and if this is a one time thing, you'd be using time that wouldn't offset the convenience.
It basically consists of a power source, rheostat, piano wire, some lamp cord and a wood frame.
Essentially the piano wire is strung between the open ends of a wood frame you construct in a u shape. The ends of the piano wire are connected to the power source. The rheostat adjusts the heat range (voltage to the wire).
This baby cuts like butter.
If you or anyone here, ever want to make one let me know and I'll draw up some plans and give you a build sheet.