Reddit reviews Woodland Scenincs - Hot Wire Foam Cutter - 9VAC

For those who are looking: It's also pink, though the blue foam tends to be thicker. It's insulation foam, so you'll find it in that aisle.

Edit: looks like this or this. The links are for 2" thick, but you can get thinner if you'd like (I prefer 1" thick because I can always double up).

Edit 2: The insulation is polystyrene but it's not made up of small beads like polystyrene packaging. That being said, it does sort of have a "grain" to it, so you'll notice cutting it one way had more resistance than the opposite way. I suggest getting a foam cutter like this. You won't be able to do large pieces (which you can cut our with a utility knife) but it makes it easy to create the chips you see in the original post.

I cut my case foam earlier this year with this wire cutter with good results.

I did end up adding a scope to the rifle after I made the initial cuts and had to trim the foam some after the fact. I used one of these razor knives for that work.

All in all mine came out ok but I'd have it professionally done if I were to do it again. The trick with the wire cutter is smooth, fluid movements. Don't stop once you're going or you'll end up with jagged spots.

Best way to cut foam: http://www.amazon.com/Woodland-Scenics-Wire-Foam-Cutter/dp/B0006KSMEU/ref=sr_1_1?ie=UTF8&qid=1344904163&sr=8-1&keywords=hot+foam+cutter

OK SO two critical things cutting foam.

1. Make sure your knife is very sharp. If its not sharp the metal will pull the foam and cause it to rip. That's the look you have now. I use retractable utility knives because you can break the blades off (do it safely) and constantly have a sharp knife. If you want to put some money into it for some REALLY nice cuts, use a hot knife or my personal favorite a hot wire cutter
   
   
2. Cut at a low angle. Do not hold the blade straight up, give it a low-to-the-surface cutting angle on top of a self repairing cutting board. Not like a wood one.

Hehe. Interestingly, this is where my hobbies collide. If you want to work with Styrofoam, THIS is what you need: http://www.amazon.com/Woodland-Scenics-Wire-Foam-Cutter/dp/B0006KSMEU

I learned this making terrain for miniature games like Warhammer.

I've spent a lot of time reading up on these this past week and from what I understand it will cut through heavier foam rather easily (as long as you have enough power and your nichrome wire isn't too weak), although the project will require $50-70 in parts and you'll have to wire your own power supply (premade power supplies like model train transformers tend to be unreliable and too weak to power hot wire cutters).

But if neither of those are a problem, it seems like a great solution.
Or you could buy a hot wire cutter already made for $30

Best of luck!

Here's an example! These devices heat up a taut wire and the wire basically melts a straight line away as you pull it through the foam!

Polystyrene foam insulation. Depending on who they buy it from, your local store may have it in different colors, so don't worry if its blue.

Best thing for cutting it is a "hot knife," a wire knife which is heated by electrical current running through its core. But this will give off fumes so only cut it outside. here's an example:
http://www.amazon.com/Woodland-Scenics-Wire-Foam-Cutter/dp/B0006KSMEU/ref=sr_1_4?ie=UTF8&qid=1367415228&sr=8-4&keywords=styrofoam+knife


You can also cut it with a pocket knife or a saw. Serrated blades work better but it makes a hell of a mess either way.

A lot of spraypaints will melt it (which gives off more fumes) so be careful how you paint it. I generally use craft paint from a hobby store (cheap!) or home depot wall paint (even cheaper!). Elmers glue works great on it as well.

oh nice yea those definitely look handy for getting clean precise cuts.
It would be a good investment if I find myself really liking to build boards. Would something like https://www.amazon.com/Woodland-Scenics-Wire-Foam-Cutter/dp/B0006KSMEU do the trick?

Honestly buying one isn't bad either. I have this one:
https://www.amazon.com/dp/B0006KSMEU/ref=cm_sw_r_cp_apa_KkGDzb8PB0QN9

$31 dollars

This is the prebuilt option, but I have an old style one that is literally 1 D battery completing a circuit that passes over a 1mm wire, and it's literally all you need. You could buy the $35 version, or make your own for pennies if you are a little bit industrious.

I will share photos of the one I have (didn't make, but it is simple enough that I could) that wouldn't cost you $5.