The Foam Factory

THIS IS NOT MY OWN DESIGN, this was made by Grant Thompson - "The King of Random"

If you want to build one heres the link: https://www.youtube.com/watch?v=N2n_EbRzZ0g

List of Materials

5ft of 3/4in PVC  $3
2x 3/4in PVC Elbows $5
2x 3/4in PVC End Caps $5
OOK Hangin Wire $5 
6ft Power Cord 
600Watt Dimmer Switch $6-$10
Metal Electricle Box $1
One 2x4 $3-$5
Wood Screws $5-$10
12Volt Power Transformer- This piece is somewhat hard to find, now a standard 16volt power transformer for a doorbell is just fine. Prices vary from around $15 to $30

This build took us a couple of weeks to put together and it turns out to be way worth spending that much time on it. The build uses 2x4, Medium Density Fiberboard (MDF) 3/4 inch PVC some hanging wire which can be found at Micheals Craft Store, a 12v power transformer, 10 amp fuse, some wood screws and a latch to close it all up. The final product is very visually appealing and stores easily.

Here is the power transformer and the project box which houses all of the power (120volt) going in and the power coming out (24volt for my transformer) going to the hotwire.

The last three pictures ahow how compact and portable the unit is. Everything you need to run this can be folded up into one compact unit for storage.

The complete ready to run hot wire cutter.

The hardest part of this build this is getting the power transformer. I used a 24v 40w power transformer. Just a little over kill. You should be able to buy one on ebay or amazon. Call your local radio shack and see if they have one, our radio shack didnt so I had one laying around deep in our electrical box and was perfect for the job.

Now what will this cut?

If you crank it up about half way this thing can glide through pink insulation foam, if you turn it up to 75% this thing will cut right through DTFB, and almost all the way up this could cut a pencile in half (if you're patient)

This thing glides right through DTFB creating such an edge very similar to the Speed Build Kits.

If you've ever looked at the edge of a speed build kit you will notice that the paper sticks out further than the foam.

Using a straight edge against the foam it will create near perfect stright lines.

 So all in all is it totally worth building one of these? Thats up to you, these things are great to use on solid foam core models, but are impratctical for cutting out DTFB planes. You could try cutting out the power pods with this, and maybe you would save some time, but nothing beats a nice sharp X-acto blade.