I recently decided to try to build an RC airplane and needed a clean and effective way of cutting the foam I will be using for the plane. After some research I decided that a hot wire foam cutter would be the best solution.
I wanted something that would be able to produce clean, even, reproducible cuts so a hand help cutter was out of the question. I ended up going with a band-saw type of design.
Step 1: Tools & Materials
>2x4- x2 18" pieces & x2 15" pieces
>1x2- x3 15" piece
>Sheet of some sort of flat surface- I used 1/16th ply board
>Drywall Screws- 1-1/4" & 2-1/2"
>Adjuster Bolts- 2" (top) & 4" (bottom) + nuts
>Metal Plate Roughly 4" square + 2-1/2" Bolts (optional)
>Wire tensioner spring + Washer (Of equal outer diameter)\
>Shaft (Of inner diameter equal to above OD)
>Some sort of bead (I used a fishing lure sinker)
>Thin Steel Wire
Saw (Ideally mitre saw or circular saw)
Drill (with some drill bits)