Fellow hot wire foam cutters, please feel free to weigh in.

cyclone3350

Master member
I guess what I was wondering is how much power was left in your setup? Is there enough power available to cut 2" foam with a bow twice as long?

Here is a calculator that seems to fit what is being used on this forum. https://jacobs-online.biz/calc2.html @Taildragger is using 7.4v on his 12", @KN4IUU the same for his 10". I have a 36" @ 23v & an 18" @ 11v. using a 28gauge wire. For the calculator temp, use 700. A standard wire is nichrome 60 with an average gauge of 28 & don't worry about filling in the other values to get an estimate. My guess is that it would take a 4s to run a 24" bow.
 

FlyingTyger

Elite member
Here is a calculator that seems to fit what is being used on this forum. https://jacobs-online.biz/calc2.html @Taildragger is using 7.4v on his 12", @KN4IUU the same for his 10". I have a 36" @ 23v & an 18" @ 11v. using a 28gauge wire. For the calculator temp, use 700. A standard wire is nichrome 60 with an average gauge of 28 & don't worry about filling in the other values to get an estimate. My guess is that it would take a 4s to run a 24" bow.
Thank you. That is what I was trying to figure out. I'd like to be able to cut wing panels that are 30-40".
 

cyclone3350

Master member
A 24" should do it no problem. If U look @ pg.1 here, I did that Cassutt Racer (my first foam wing) with a Hobby Lobby 8" making a 24" WS out of 4 pieces. My Gee Bee Is 60" & 6 panels. If U R good as to how precise U put your patterns, these panels lined up nicely with very little sanding to blend. Form what I've seen of your work, your cuts probably won't require any sanding to blend.
 

FlyingTyger

Elite member
yeah I don’t see a post button
1643996950800.png
 

Off-topic jes

Elite member
Got them!
 

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cyclone3350

Master member
My Foam Cutting project is done!

The wings for my Gee Bee that is. The rest of it is all traditional balsa build. This was an interesting experiment with mostly positive results. I had three objectives. 1) can this have the look of a balsa build up when covered. I would say yes. 2) will it be light & strong. @ 26.70 oz as shown, not bad for a 60"WS. & Oh God this thing feels solid. 3) will it save time. Eah, for my first time doing this, It did take much longer than anticipated. Now that I some techniques down, I am hoping the next one will fair better for me. A couple of learning curves here. To make the slots for the stringers, I use guides & the hot wire bow. This worked out very well. I've also did this for the aileron wire tube. I did a test to see how well the tube would fit. I also did not want the cut out to run the length of the wing, so I wanted to see if could glue back the part that I did not want to cut out. The cut out plug fit back perfectly. I am using blocks of plywood for the main gear wire to fit in and will be held in place with metal gear straps. I made side panels in the shape of the dihedral and used them to join the gear blocks. The cut outs for these, I did with a method of cutting little squares into the foam & scooping them out as shown for the servo cavity. Epoxy joined everything together & a 9oz fiberglass 2" wide strip epoxied, completes it. I think I am going to do a 1/4 Ansaldo SVA using these type of wings with a FB fuse for the Dawn Patrol Challenge. Hmmm,,, we shall see :unsure:

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