Intro
In this project, you’ll build a simple yet effective hot wire foam cutter using basic PVC and nichrome wire. This tool helps in cutting thermocol/foam accurately for building custom RC airplane parts.
Materials Required
PVC Pipe – 5ft
PVC Elbow Joints (2x L-shape)
Nichrome Wire or Heater Element
Wooden base or PVC frame (optional for stability)
Wires for connections
Power Source (Battery/adapter, 12V preferred)
Soldering iron, zip ties, tape
Tutorial Steps
Step 1: Frame Building
🧰 Cut the PVC pipes into appropriate lengths to form a rectangular “U” shape. [Image 2: PVC frame structure being assembled]
Connect elbows to form the top bar with vertical supports.
You can optionally attach the setup to a wooden board for better stability.
Step 2: Attach the Nichrome Wire
🧵 Stretch the nichrome wire horizontally across the open ends of the “U” shape.
Keep the wire taut. You can use screws or bolts to secure it.
Make sure not to over-tighten as it will expand on heating.
Step 3: Electrical Connections
⚡ Connect two wires to each end of the nichrome wire.
These wires go to your power supply (battery or adapter).
Use heat-proof wire and ensure insulation.
Step 4: Power & Testing
🔌 Connect the power source and check if the wire heats up.
Be careful—nichrome wire gets very hot! Test by running a foam piece gently.
Step 5: Cutting Foam
✂️ Now start cutting foam shapes for your RC airplane body or wings.
Move the foam, not the wire, to avoid slack or breaking the wire.
⚠️ Safety Tips
Don’t leave the cutter on unattended.
Work in a ventilated space to avoid inhaling melted foam fumes.
Use gloves and keep away from kids.
Finished Result
📌 Additional Notes
Use a 12V adapter or battery for best performance.
Nichrome wire can be salvaged from old toasters or purchased online.
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