A cheap and easy hot wire cutter for any RC modeler who needs to cut pieces of foam from a sheet or block.
Step 1: Get You Your Materials
A box with foam packaging inside for mounting the cutter
A hand held hot wire cutter, available from micheals in the foam section, costs about $20 unless you use a coupon.
A hot glue gun and extra sticks (not pictured)
A stanley or Xacto knife
marker, to mark foam
Step 2: Cut Mount for Cutter
use a marker to outline the hole you want to cut out, i used the center hole for the mount hole. as you cut out the hole with the hand cutter keep the circle that is left this will be used later on for to mount the cutter. you need to cut a smaller hole in the middle of the cut circle you just cut. can see in the picture that you need to cut a piece off to make it a circle. Then make sure that the hole is big enough to fit the small shoulder on the cutter like in the pic.
Step 3: Mount Cutter and Make Reccess in Foam
next you need to cut a large hole in the bottom chunk of foam where the handle of the cutter will be. the end of the cutter that the power supply plugs into will be at the bottom of the box so you need to cut a hole in the bottom of the box where you will add legs to hold it up so you can plug it in.
to mount the cutter put the mount ring on, but don't glue it, then place the mount in a place where the edge of the metal mount piece on the cutter is flush with the top of the foam. mark it with a marker and glue just the ring in place and add a few pieces of scrap foam to reinforce the joint.
Step 4: Mount Cuter and Feet
after you mount the mount ring it is time to hot glue the cutter in the mount. start by sliding the cutter on and making sure it is straight up, then add a few dots of glue to the bottom of the ring and put it in, hold the cutter and check the alignment as the glue dries. after that make sure you get rid of the kitten that might be inside the box before you put the foam back in. (JK! =P) then cut a hole in the box for the plug on the cutter like in the picture. and cut a hole in the top for the cutting rod to go through.
Step 5: Finishing Steps
next use some pieces of foam from the packaging and cut 4 equal cubes or rectangles for the feet make sure they are at least 1"-2" long and glue them to the bottom of the box. then make sure the cutter's switch is on so you can plug in the power supply included with the cutter when you want to use it then simply unplug it to turn it off.
you are done! now enjoy the endless possibilities of using your hot wire cutter table!