Foam coring? tools / methods

[ddlstang]

I'm sure someone has a thread on here but was wanting input on everyone's methods and tools they use on coring out foam wings and other pieces.

Was trying to find a good cutting tool.

Thanks

[rcpilot82]

Soldering gun with a piece of 12 gage copper wire (ground wire in romex 12-2)
forestner bits
you can make a little hot wire bow

[MODE 1]

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[rcpilot82]

Also another reason is if you are vac-bagging a wing or tail, sometimes if you core before sheeting you will get "dimples" in the sheeting where there is no foam.

[MODE 1]

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[rcpilot82]

Not to get off track, but the reason I VB is because I have a bad back that dosen't like cinder blocks too well. and It's another toy to play with

[ddlstang]

Mode1, what do you use to power your home made bow?

[MODE 1]

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[MODE 1]

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[rcpilot82]

All good points and info

[Walt]

For servo wire holes in foam wings I use a soldering iron with the wire bent as shown in the gun. I use this with an aluminum straight edge and it makes perfect holes in wing cores for wiring. The other copper U shaped fits in the gun also. I use this for removing foam from tail fillets area's on foam turtle deck extensions. For hatch covers I use a Variac transformer with a wire arrangement as shown. There's 2 vertical standoffs clamped to my bench made from hard oak and 2- #10 machine screws. Between these stretch a Nicrome wire or .030 stainless MIG wire. I make end templates, 3M77 them with pins to the ends of whatever I"m cutting and hold the piece in my hand and run them through the wire. Its easier than a bow doing this method for hatch's and 1/4 rounds used on motorbox's on Cardens. The templates I make from Formica purchased from Lowes. I'll be using this shortly on my current build thread when I get to this part of the build. It works very well and is super simple to make and use.

[Rush7]

	Quote: Originally Posted by Walt
	For servo wire holes in foam wings I use a soldering iron with the wire bent as shown in the gun. I use this with an aluminum straight edge and it makes perfect holes in wing cores for wiring. The other copper U shaped fits in the gun also. I use this for removing foam from tail fillets area's on foam turtle deck extensions. For hatch covers I use a Variac transformer with a wire arrangement as shown. There's 2 vertical standoffs clamped to my bench made from hard oak and 2- #10 machine screws. Between these stretch a Nicrome wire or .030 stainless MIG wire. I make end templates, 3M77 them with pins to the ends of whatever I"m cutting and hold the piece in my hand and run them through the wire. Its easier than a bow doing this method for hatch's and 1/4 rounds used on motorbox's on Cardens. The templates I make from Formica purchased from Lowes. I'll be using this shortly on my current build thread when I get to this part of the build. It works very well and is super simple to make and use.

Love the expalnations but I have got to ask one thing. Where in the world did you come up with that old Variac. That thing has some years on it.

[ddlstang]

Thanks Walt, I have the soldering iron that I use for the wire slots - works great. I was wanting to do some coring of the wings and tail feathers and just wanted some other ideas. The main thing I was unaware of was the proper way to power a bow or other item. I may end up using a hole saw and cleaning up with a drum sander - a lot messier though.

[Walt]

	Quote: Originally Posted by Rush7
	Love the expalnations but I have got to ask one thing. Where in the world did you come up with that old Variac. That thing has some years on it.

A good friend of mine used this for years and didn't need it anymore. I was using a 110 outlet with a light dimmer on it. It would basically smoke through the foam. He saw this and gave me this Variac, it works very well and holds heat control much better than the old light dimmer did..

[ddlstang]

Walt just clued me into the perfect tool.
$30 for the knife and $20 for the power supply.

http://www.cstsales.com/foam_factory.html

Thanks again