How To Cut Depron and Other Foam
10-05-2008, 09:33 AM
#1
Super Contributor
Thread Starter
Join Date: Oct 2006
Location: Hesperia, So. Calif
Posts: 19,255
How To Cut Depron and Other Foam
Hi Everyone 
A Lot of Beginner Scratch Builders are Having a Difficult time trying to cut Depron and other Foams, I have been asked, how do you cut it so its a Clean cut, and I have seen pictures from other beginner scratch builders, and the cuts on their foam planes is ragged, pulled & torn, So I Know others are Struggling with Cutting foam, here is what I have learned, that works and makes some nice clean cuts, I will post the info on the pics, and Please add to this Thread, any Tips and Tricks that You may have learned along the way, to Help Others with their Build, Thank You, Take care, Chellie
the tools to use.
1. Large Handel Xacto knife holder, easier to hold and control
2. # 2 Xacto Blades, I have had the best luck with these blades, use a new blade for every new project
3. A Metal Straight Edge/ Ruler, a must, and guide knife into ruler so it does not drift off.
4. Masking tape, Tape the ruler to the foam, and cut right through the tape.
5. Most Important, Take your time, Cut Slow, Dont try to cut the foam with one cut, it wont work, It Takes a Minimum of 3 cuts to cut depron Clean, Dont rush it, hold knife at a 45 Degree Angle.
6. These cutting Hints, will work on foam board and other foams as well.
7. Cutting Board, Compressed Partical Wood Board, about 5/8" to 3/4" thick, Home depot has it.
8. Keep Hand away from Blade Path, keep holding Hand above knife and cut away from holding Hand
Hope that helps to insure a nice build, Now, Go Cut some foam
and Be careful, Blood is Hard to get out of Foam 
A Lot of Beginner Scratch Builders are Having a Difficult time trying to cut Depron and other Foams, I have been asked, how do you cut it so its a Clean cut, and I have seen pictures from other beginner scratch builders, and the cuts on their foam planes is ragged, pulled & torn, So I Know others are Struggling with Cutting foam, here is what I have learned, that works and makes some nice clean cuts, I will post the info on the pics, and Please add to this Thread, any Tips and Tricks that You may have learned along the way, to Help Others with their Build, Thank You, Take care, Chelliethe tools to use.
1. Large Handel Xacto knife holder, easier to hold and control
2. # 2 Xacto Blades, I have had the best luck with these blades, use a new blade for every new project
3. A Metal Straight Edge/ Ruler, a must, and guide knife into ruler so it does not drift off.
4. Masking tape, Tape the ruler to the foam, and cut right through the tape.
5. Most Important, Take your time, Cut Slow, Dont try to cut the foam with one cut, it wont work, It Takes a Minimum of 3 cuts to cut depron Clean, Dont rush it, hold knife at a 45 Degree Angle.
6. These cutting Hints, will work on foam board and other foams as well.
7. Cutting Board, Compressed Partical Wood Board, about 5/8" to 3/4" thick, Home depot has it.
8. Keep Hand away from Blade Path, keep holding Hand above knife and cut away from holding Hand
Hope that helps to insure a nice build, Now, Go Cut some foam
and Be careful, Blood is Hard to get out of Foam
Last edited by CHELLIE; 10-06-2008 at 08:31 AM.
10-06-2008, 02:05 AM
#2
What a Blast!
Join Date: Jul 2007
Location: Atlantic Canada
Posts: 252
I have to add to Chellie's post that you really do have to keep your fingers out of the way! I laughed at Dave Power's video on YouTube some time ago where he shows how he cut his finger while being intent on his build, but it sure wasn't funny when I did it to myself a few weeks ago. Fortunately my finger recovered and I'm back on the case...
Rick
Rick
10-06-2008, 02:18 AM
#4
Super Contributor
Thread Starter
Join Date: Oct 2006
Location: Hesperia, So. Calif
Posts: 19,255
Originally Posted by RocketMan
I have to add to Chellie's post that you really do have to keep your fingers out of the way! I laughed at Dave Power's video on YouTube some time ago where he shows how he cut his finger while being intent on his build, but it sure wasn't funny when I did it to myself a few weeks ago. Fortunately my finger recovered and I'm back on the case...
Rick
Rick
Be careful Rick, Glad your all better now I have cut myself too, but not real bad, yes its going to happen, if your not extra careful, ask me how i know Take care, Chellie
10-06-2008, 02:20 AM
#5
Super Contributor
Thread Starter
Join Date: Oct 2006
Location: Hesperia, So. Calif
Posts: 19,255
Originally Posted by gfdengine204
Chellie,
What kind of board are you cutting on?
What kind of board are you cutting on?
10-06-2008, 02:30 AM
#7
What a Blast!
Join Date: Jul 2007
Location: Atlantic Canada
Posts: 252
Originally Posted by CHELLIE
Ouchy Be careful Rick, Glad your all better now I have cut myself too, but not real bad, yes its going to happen, if your not extra careful, ask me how i know Take care, Chellie
Be careful Rick, Glad your all better now I have cut myself too, but not real bad, yes its going to happen, if your not extra careful, ask me how i know Take care, Chellie
.
10-06-2008, 02:46 AM
#8
Castor
Join Date: Jan 2007
Location: Oklahoma
Posts: 71
A good cutting board material is gypsum board or sheet rock. I use it as a sacrificial cutting surface over my build table. The gypsum board has one additional characteristic that make it worth using. It will not warp with changes in temperature and humidity.
10-06-2008, 06:02 PM
#10
Super Contributor
Join Date: May 2007
Location: Sandwich, IL
Posts: 9,565
So is there any difference between cutting foam with the #2 blade and a retractable knife? Say something like this:
http://www.stanleytools.com/default....ractable+Knife
http://www.stanleytools.com/default....ractable+Knife
10-06-2008, 06:45 PM
#11
Hotel California
Join Date: Sep 2007
Posts: 1,456
Originally Posted by gfdengine204
So is there any difference between cutting foam with the #2 blade and a retractable knife?
10-06-2008, 07:39 PM
#13
Hotel California
Join Date: Sep 2007
Posts: 1,456
Originally Posted by gfdengine204
What's the tungsten rod for? A straightedge?
10-07-2008, 01:39 AM
#15
Super Contributor
Thread Starter
Join Date: Oct 2006
Location: Hesperia, So. Calif
Posts: 19,255
Originally Posted by gfdengine204
So is there any difference between cutting foam with the #2 blade and a retractable knife? Say something like this:
http://www.stanleytools.com/default....ractable+Knife
http://www.stanleytools.com/default....ractable+Knife
Hi Kev
the #2 blade is long and thin, it does not have a lot of surface area to drag on the foam, the box cutter should be ok with up to 6mm foam, but with 9mm, it might start to hang up on the edge, just my 2 cents worth the #2 blade looks like the one on the right.
10-08-2008, 03:03 PM
#19
Ya' need to use mo rudda!
Join Date: Jan 2008
Location: Chino, Calif. aka Dairyland
Posts: 1,380
What a timely thread Chellie, thanks, the 2nd contest entrants will surely benefit
OK, my 2% worth........when cutting out your shapes and whatnot, you may notice the blade tends to tuck (away from 90 deg) sometimes.... making your cut angled a bit. Most likely the cause is that you're putting too much down pressure on the tool, I was 100% guilty of this one, not letting the blade do it's work and trying to bore through the cut in one pass. You just cannot rush these cuts......I know! :o:o
Angle your blade back a bit near 45 deg and "pull" the blade through the cut. This almost assures that you won't press too hard on the tool since your leverage on the blade is decreased.
Remember though too that all these foam materials are sandable.....you can fix most any oopsy pretty quickly.
be safe, have fun and more importantly get something flying!
oh yeah
--Ray
OK, my 2% worth........when cutting out your shapes and whatnot, you may notice the blade tends to tuck (away from 90 deg) sometimes.... making your cut angled a bit. Most likely the cause is that you're putting too much down pressure on the tool, I was 100% guilty of this one, not letting the blade do it's work and trying to bore through the cut in one pass. You just cannot rush these cuts......I know! :o:o
Angle your blade back a bit near 45 deg and "pull" the blade through the cut. This almost assures that you won't press too hard on the tool since your leverage on the blade is decreased.
Remember though too that all these foam materials are sandable.....you can fix most any oopsy pretty quickly.
be safe, have fun and more importantly get something flying!
oh yeah
--Ray
10-09-2008, 09:23 PM
#20
Member
Join Date: Jan 2008
Posts: 47
Oct2633
Originally Posted by CHELLIE
Hi Kev the #2 blade is long and thin, it does not have a lot of surface area to drag on the foam, the box cutter should be ok with up to 6mm foam, but with 9mm, it might start to hang up on the edge, just my 2 cents worth the #2 blade looks like the one on the right.
the #2 blade is long and thin, it does not have a lot of surface area to drag on the foam, the box cutter should be ok with up to 6mm foam, but with 9mm, it might start to hang up on the edge, just my 2 cents worth the #2 blade looks like the one on the right.
? It's about the only thing I cut foam with (other than a hot wire). They do dull easily and several may be used to cut out one plane.
10-09-2008, 09:58 PM
#21
Super Contributor
Thread Starter
Join Date: Oct 2006
Location: Hesperia, So. Calif
Posts: 19,255
Originally Posted by oct2633
Chellie, the #2 blade on the right looks exactly like the #11 modeling blade I commonly use. Is that correct? It's about the only thing I cut foam with (other than a hot wire). They do dull easily and several may be used to cut out one plane.
? It's about the only thing I cut foam with (other than a hot wire). They do dull easily and several may be used to cut out one plane. The #2 Blade is a heavier duty blade than the #11, the #11 blade is for doing fine cutting with, and will get dull much Faster, the #2 blade is for heavier duty cutting, Hope that helps, Chellie
Last edited by CHELLIE; 01-31-2009 at 05:27 AM.
10-09-2008, 11:17 PM
#22
Super Contributor
Thread Starter
Join Date: Oct 2006
Location: Hesperia, So. Calif
Posts: 19,255
A Quick Tip, To sharpen your Xacto blade, I use a piece of 400 grit sand paper, lay it on the edge of my cutting board, and hold the blade at a 15 degree angle, and draw it a few times on both sides, works great, Hope that helps, Chellie
01-31-2009, 05:01 AM
#24
Super Contributor
Thread Starter
Join Date: Oct 2006
Location: Hesperia, So. Calif
Posts: 19,255
Cutting Polystyrene or Styrofoam
Hi Everyone when Cutting Polystyrene or styrofoam, use a hot wire cutter, Michaels Arts and crafts has them,
A Hot wire cutter is the best way to go
http://www.wattflyer.com/forums/show...ot+wire+cutter
http://www.spacemodeling.org/new/how_to/Foam_Cutter.htm
http://www.wattflyer.com/forums/show...ot+wire+cutter
http://www.youtube.com/watch?v=2Dk7S5UmgRQ
when Cutting Polystyrene or styrofoam, use a hot wire cutter, Michaels Arts and crafts has them, A Hot wire cutter is the best way to go
http://www.wattflyer.com/forums/show...ot+wire+cutter
http://www.spacemodeling.org/new/how_to/Foam_Cutter.htm
http://www.wattflyer.com/forums/show...ot+wire+cutter
http://www.youtube.com/watch?v=2Dk7S5UmgRQ
01-31-2009, 05:18 AM
#25
Super Contributor
Thread Starter
Join Date: Oct 2006
Location: Hesperia, So. Calif
Posts: 19,255
[media]http://www.youtube.com/watch?v=03u1Hf7Dm5I[/media]
http://www.youtube.com/watch?v=ME0WgH-AAdc
http://www.youtube.com/watch?v=ME0WgH-AAdc
Linear Mode
