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 I've always planned to build a foam cutting device but when the time came I was short on time and too cheap to build a machine. This Instructable was created to help anyone looking for a super easy low tech method to make clean styrofoam cuts. Its much more effective than using a razor blade or hand saw and doesn't leave leave little foam bunnies all over the place. This method works especially well for making straight cuts and after gathering your items, you will literally be cutting styrofoam in less than 5 minutes. 

Materials you will need.
1 wire hanger
1 Propane torch 
1 lighter or other ignition device
1 pair of vise grip pliers
3 pieces of scrap 2 x 4 lumber


Step 1: Making the cutter

Bend the curved neck of the hanger straight then attach your vise grip pliers to the end. Lying the hanger on the ground while clamping the vise grips onto the end will help make your cutting tool more uniformed. 

Alternatively you could create any shape with the wire hanger to fit your needs. Making a box shape would also work quite well. 
<p>Based on the instructions here, I did this. I was cutting 1&quot; styrofoam, 2 feet across.</p><p>I did not unbend the coat hanger, nor was there any need for vice grips. The hook part stayed quite cool. Also I did not use a wood piece as a guide (fence), instead I just scored the top to make a line which I followed. I admit the finished product was not a nice clean straight line but it was good enough for my purposes.</p><p>Maybe it was because of the size and thickness, but I could only go ~4 inches before having to reheat the wire. What worked for me was heating about half of the long part of the triangle and then using a sawing motion to bring freshly hot wire into play - that got me a lot farther per reheat.</p><p>Note on recycling - stryofoam is not recyclable in most jurisdictions.</p><p>Having previously use a hand saw and ending up with loads of styrofoam dust, this method is way better.</p>
Good one and very simple and low tech.
YaHoo! Now we're cookin'. Too easy. Thanks
Does this off-gas a lot? I always use an electric meat carving knife and it works well.
There is a slight amount of it when you are making your cuts. If you watch the video you can see a little bit of it. I would say there is more when you are reheating your wire and there is a bit of styrofoam left on it.

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