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in file /includes/functions_reimg.php on line 126: Invalid argument supplied for foreach() WorldWorksGames • View topic - Hotwire Cutting Tlinx Mounts
I've been meaning to try this out for a while as I used to do something similar when cutting out Rc plane templates and it seems to work well for Tlinx templates as well.
The foam material I used was Depron, all I could get hold of locally in the past I've used cellfoam88 (for planes) which is a little tougher than Depron but for tlinx templates either should do. It comes in sheets of 6mm (just under 1/4 of an inch) and for me in Aus it costs a little more than foamboard. It should be avaliable from any good RC plane/model shop but you may need to ask for it as it's normally stored out the back.
Fist up you will need to build a hotwire foam cutter, mines constructed from old MDF and uses a nichrome fishing lure trace as the cutting wire costs about $5 for a few meters, other than that my cutter just cost me time to build a few years ago, here's mine:
The power is a laptop multivolatge adaptor which gives me a range of 15volts to 22 volts, you control the wire temp by increasing and decreasing the voltage, mines very crude but it works . Here's were I got the plans from:
http://www.hhhh.org/~joeboy/resources/h ... utter.html If you do build one don't worry to much if it's not quiet right the important bit is only the correct wire and that it's vertical.
First up I had robo cut me a nice blank template and for ease of photographing I cut a small square of Depron. You can just glue templates over a full sheet and cut it up using the hotwire then trim them down using the hotwire again, bit like using a bandsaw:
Glue the template on the foam, It's very important the template has no bits of cardboard hanging of it as the hotwire can't cut or even push cardboard out of the way so the template must be clean :
Then you set the voltage on your power supply and cut (mine was set to 15v but 14v would have been better as the wire was a little hot, need to add a little more Resistance , still they have been turning out fine)
You can tell when you reach the correct temperature as the wire slips through easily but only makes a cut line about as thick as the wire is, you don't wont it melting a huge channel as that would undercut the template:
Close up of an edge:
It is a little quicker than cutting by craftknife, plus no hand cramping or slippage. There is also a bucketload of DIY auto foamcutter plans out there so you could if inclined build your own auto-cutting table, no need for templates then stick the piece of foam on and run the program:).
Durability wise once wrapped I can't tell the difference between a foamboard tile and a Depron tile. Anyways I'm going to cut all my tiles like this now and save my hands/wrists .
For more info just google hotwire foam cutter/ing
edit: I just did a bit of hunting around and seems you can by small tabletop bandsaw cutters now commercially. Been awhile since Ive been interested in cutting foam, they look nice but a bit pricey at around $99
Sets : To many, but not as many as some
Last edited by Sirrob01 on 10-18-2010, 08:25 PM, edited 1 time in total.
I experimented a bit with expanded bead foam, a few years back, but was disappointed with the results. This looks like a much more successful effort. Mind you, I was experimenting with the beaded foam because I could get a whole bunch of it for free....
The Auld Grump, I have always been fond of the non-statement 'anything free is worth what you pay for it'. That can be read so many ways....
Nullum magnum ingenium sine mixtura dementiae fuit.
Last edited by TheAuldGrump on 10-18-2010, 06:05 PM, edited 1 time in total.
yes the beaded foam stuff is horrible to cut, I remember trying to cut some stuff from it, just ended up with a mess .
I got a little tired waiting for my printer to print and cutter to cut so I made up an MDF Tlinx template and simply placed this on the foam and cut around it for each mount. Used to do this for planes if you were making 2+.
I am not sure on the durability at this stage, have to see after they are wrapped, I suspect they will be fine as I'm going to end up with effectively foamboard once wrapped. Here's the first 24 (okay 23 in the pic) cut for my hinterland build which needs 64...
i got 24 out of one piece of depron so about 60c each. I'll have to buy 2 more sheets tomorrow. The above took a little under 3 hours to cut, a fair bit quicker than I can do foamboard ones..doubt I'd have had all the templates glued on in 3 hours , I was getting significantly quicker at the end and cut the last 8 in about 35mins.
I'll keep updating how it's going as the build progresses.
Pretty low quality and my hands in the way for the first min or so (sorry I couldn't cut backhanded), Skip to 1:30 to see the notch cutting.
The wost thing about hotwire cutting is the smell, sort of burnt plastic and it can give you a headache if the rooms not well ventilated. I tend to just wear one of these while cutting:
(Summary -Protector Multi Mate Dust/Mist/Fumes/Odours Mask 2 Pack Pack of two P2GV class masks that provide protection dust, mists and fumes as for P1 and P2)
gets rid of most of the fumes and very cheap
Back to cutting for me almost have the 80 I need for hinterland layout
Piston Joined: 07-30-2004, 08:41 AM Posts: 449 Location: USA
That looks like a good way to cut a bunch of those tiles. The video really sets it off.
Have you tried buying bottles or cans of rubber cement and applying it to the cardstock tiles with a small roller or some other tool to spread it? It seems like that would be cheaper than buying those spray cans of 3M adhesive. Contact cement might work too, but that is usually a one shot deal so you have to be real careful to line things up when you join the two parts.
I'm probably exaggerate the fumes a little as I've never heard any other person who cuts foam complain. Of course I'd estimate the number of cuts I've done for 80 tlx tiles would equate to 3-4 planes, so the volumes much higher . I also tend to er on the side of caution as I've had to many near misses in the past 12 months .
Yeh glues a bit of pain, but that seems to be my bugbear whether it's depron or foamboard tiles. Any water based glue seems to warp the tiles (although PVA glue bonds never seem to fail). The usual glue sticks people are using just don't hold up for me under the massive temp range we get downunder, even the 3m77 stuff has failed on some of my earlier non-tlx tiles. I'm thinking of trying to shoot some contact adhesive out of a cheapy mini airbrushing gun I know upholsters do this just need to work out how and the costs/materials .
I'm out of depron again (and low on funds, time to raid the change jar ), so I'm a bit stuck, 80 tiles ready for hinterland but I'll wait for new hinterland before proceeding. I'll probably start cutting the 300 odd tab connectors I need.
edit: sry missed Talae's question - At the moment I'm only cutting one at a time as I'm getting a nice bevel on the edges
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