Whats the cheapest and fairly easy way to cut foam for scenery!!!
Thanks everyone
Raptor55
It depends upon what you are trying to cut and how much. I’ve tried almost every tool out there. I’ve even used a full size wood crosscut saw to cut through foam that was 16-18" thick. I’ve used an electric knife too. It works well but the motor gets hot. My favorite right now is the 6" hot knife with a wooden handle. Many folks make them. Look around for the least expensive. You ought to be able to find one around $40, if you look hard. I’ve also used hot foam wire tools from Woodland Scenics and the Hot Wire Foam factory. The Hot Wire Foam Factory has the biggest selection. I did not like the Woodland Scenics tool but I had large cuts and lots of them.
Hot knife is the way to go, you have greater control and doesn’t leave a mess. I do advise you to either cut in a good ventilated area, or if this is not possible, use a fan to expel any odors. Also, do not run the temperature up on the knife any more than necessary to cut/melt the foam, less odors and knife doesn’t get unduly heated.
I used a battery powered jigsaw. I was using 2" foam though. I personally thought this worked terrific.
Hi Rap;
The cheapest is a serrated kitchen knife. It is not difficult to use, but rather messy.
The easiest, as mentioned above are hot wire cutters, which you can purchase or make. The least expensive route here is a Harbor Freight or similar soldering gun, and a piece of 12 guage wire flattened and trimmed in the middle.
Hot knife! [tup]
Could you expound a bit about why you didn’t like the W/S foam cutter? Thanks.
The wire is very thin. It will break easily on large cuts after you’ve made a few. It also is based upon tension and can’t be shaped like the much stiffer versions from the Hot Wire Foam factory.
I use an old bread knife from the thrift store. hold it with about a 45 degree angle to the line you are cutting and make several passes with the knife Don’t try to push too hard, just keep slicing on the same line. I get good square edges in 2" foam for my module decks. I also stack layers and cut the landforms with the same knife. After you get the basic form you can cut strata and fault lines in the surface. don’t be afraid to practice on scraps until you get the effect you want. It is messy but a few passes with the dust-buster or shop vac makes cleanup quick. I save all the larger pieces to use as humps and bumps in the landscape. Some flat latex or acrylic paint and white glue the grass, shrubs, bushes, and trees and it looks pretty good!
I just score it with box cutters and snap it off and I (usually) get a nice, clean edge without any (or very little) pieces of foam beads. Of course, this probably wouldn’t work as well with 2" foam.
All the hot wire/knives work fine, but they ain’t cheap and you did say “cheapest”.
I’ve been cutting foam for layouts for 15 years and the cheapest and simplest are the 4 for $1 (dollar stores) 6" breakaway utility knives, (extend them all the way out and use the blade lock). I keep a sharpening stone handy, (always keep your blades sharp!). Use a slicing motion rather than a sawing motion and make multiple passes. I use both the wider 1" blades (for general use) and the narrower 1/2" blades for more intricate carving. I also have an old filleting knife for certain situations and I keep it very sharp. The real secret to cutting anything with blades it to use a sharp blade, you have to let the blade do the work. Get a sharpening stone. You can use it with your Xacto knives too and extend their useful lives.
Stay away from serrated knives and saws (unless you have to cut thicker than 2"), they make a mess (foam dust). You can also use a jig saw with a metal cutting blade (smoother cut), but keep the vacum handy.
Did I say keep your blades sharp?
I mostly use a hack saw blade with one end taped up to use as a handle.
bill
An electric kitchen knife maks a very clean cut through thick material. It just gets hot after a few cuts on 2" material.
Ditto on the bread knife and hacksaw blade. I also use boxcutters and a Stanley Surefoam rasp. Don’t bother with the hot cutters: they’re too slow, offgas poisonous fumes, and are too expensive.