To make your own Styrofoam cutter, you will need some round brass welding rods, a piece of Masonite, and a piece of timber with 40 mm x 20 mm dimensions.
Steps to Make a Styrofoam Cutter
- Use the 40 mm x 20 mm timber as an undersized frame. Glue the piece of 400-mm square Masonite on it with the rim of the square Masonite extended over the two sides of the undersized frame by around 15 mm. Slide a fence clamp onto the board to enable cutting with set sizes.
- Bend the brass welding rod to a circle with a 200 mm radius. Then drill a hole in the middle-rear frame and push one end of the brass rod into that hole. Make a brass clamp out of a 2-mm brass rod. Then drill the brass clamp to slide on the 8-mm clamp. The clamp can actually take two clamping screws each with 3mm size: one will clamp a piece of element wire and the other the 8-mm rod.
- For the bottom electrode, bend a 3-mm brass rod around a 10-mm former for just about three loops. By then, a spring-like material that keeps cutting wire tensioned is formed. Bore a hole in the middle-spar of the frame. Then push one end of the rod into this hole and glue it to keep it from rotating. A clamp like that of the top rod is made on the other end.
- String the element wire in-between the clamps into a hole that is made in the board and then add a little tension. Join the wires of a charger to the bottom coiled electrode and to the rod. After this, the cutting wire will heat up and can cut foam easily. To adjust the angle of the cut, just slide the top clamp of the rod. For a fence, use a piece of light angle. Clamps and wing nuts can be attuned for the cutting size.
- You can pick up a socket from an unused item and have it fixed to the frame. Then wire the socket to the two electrodes and plug the charger into the socket.
- To have a smooth cut, do not stop the cutting wire and start again. Instead, keep it moving.