While doing some experiments with bonding foam, a simple solution to cutting and boring holes, came up.
Some may have already found this, but if you do not have a hot wire cutter, or the throat capacity of your cutter is not deep enough, the use of a 15/30 watt solder iron from radio shack (under $10 US) will melt thru quite well. After each hole or cut, the tip is easy to clean, using an old rag doubled or triple layer so as not to burn your hand, quickly wipe the tip clean.
Heat is so low, that very little fumes or smoke is generated. My tip is 3/16" round and 2" long.
For a deeper cut, i am thinking of buying a unit that has a 1/4" threaded shank, then bore a hole thru a short bolt, the hole should allow a 3" or 4" finish nail to pass thru and seat against the head of the nail. Then screw the bolt/nail head into the solder iron with the point sticking out, if heat transfer carries all the way to the end of the nail, then foam as thick as 3-1/2" can be cut.
Hope this is a help to someone, it is so simple.
RonL
Some may have already found this, but if you do not have a hot wire cutter, or the throat capacity of your cutter is not deep enough, the use of a 15/30 watt solder iron from radio shack (under $10 US) will melt thru quite well. After each hole or cut, the tip is easy to clean, using an old rag doubled or triple layer so as not to burn your hand, quickly wipe the tip clean.
Heat is so low, that very little fumes or smoke is generated. My tip is 3/16" round and 2" long.
For a deeper cut, i am thinking of buying a unit that has a 1/4" threaded shank, then bore a hole thru a short bolt, the hole should allow a 3" or 4" finish nail to pass thru and seat against the head of the nail. Then screw the bolt/nail head into the solder iron with the point sticking out, if heat transfer carries all the way to the end of the nail, then foam as thick as 3-1/2" can be cut.
Hope this is a help to someone, it is so simple.
RonL