Just finished cutting foam for my M1A

[unrealtrip]

I made a hot wire foam cutter, it was pretty easy really. Anyway, here's a couple snaps. I took more during the process if anyone wants to see I'll add them.


The other cutouts that are pending

See how close the lines are on the hammer, etc

The cutting tool

 

[Kaylee]

Awesome work! How about a materials list, sources, and some instruction?

(and um... where do the extra magazines go? )

 

[Gator]

Hey, that looks great! I did a quick Google search and found this:

http://www.hhhh.org/~joeboy/resources/hotwire_foam_cutter/hotwire_foam_cutter.html

I may try making one of those

 

[kcmarine]

Oooooh... shnazy...

I think that the mags go in the three slots underneath the handguard.

 

[unrealtrip]

Thanks- Yeah the extra 10rd mags will go in those slots below the handguard. Extra mags for the .45 will go in the extended hole where the current clip is. Those longer ones will be for rifle cleaning rods maybe. Also the sling area will be where I put the adjustable cheekpad which attaches to the stock, or maybe I'll recut and leave it attached the the rifle. I dunno.

Foam cutter:
The base and arm you build yourself out of wood, pretty easy, anyone with opposable thumbs should be able to figure out a good way to do that. I recommend a smooth laminated piece of wood for the base platform so your foam can slide on it. You can use a shelf plank, obtainable at any hardware store for a few dollars.

The power supply:
- Dimmer switch, home depot $5
- Cheap extension cord, home depot $1.25
- 3 outlet box, the blue thing, home depot $5
- 25v 2amp transformer, radio shack $10
- Old pc power cord, free

Cutting line:
- Guitar string, I had one, so free

Total investment was about $20

Assemble the power supply as shown in the pictures. Cut both ends off of the extension cord and split them a few inches on one end and a foot and a half on the other, strip the ends. Attach the short split end to the yellow wires, attach the longer split ends to the bolts on your cutting assembly. Connect the two bolts with the guitar string.

Use the dimmer switch to power on the unit and turn it clockwise to increase the power being sent through the cutting line. You can use a pocket knife or a open end wrench to guide the cutting wire as you are moving through the foam with it. Use the cutting line on a test piece of foam to get a feel for how much power you need, it should move through the foam with ease.

Trace your gun out on posterboard, make it tighter than the actual gun by a 1/4" so it is a nice tight fit. Use that as a guide for the cutting wire, try to avoid having notches in your template as the wire can get stuck in it.

NOTE: The string will stretch once you apply power to it, so either incorporate a spring into your design, or adjust the tension with the tensioning screw.

* Dislaimer: Do this at your own risk, you are working with electricity and it can be hazardous to your health.

I adjust this screw to tighten up the wire.

 

[unrealtrip]

Make your stencil:

For the pistol I didn't want it to drop in all the way, so I cut the cutout in half so I could stick it back in.