Forum adverts like this one are shown to any user who is not logged in. Join us by filling out a tiny 3 field form and you will get your own, free, dakka user account which gives a good range of benefits to you: No adverts like this in the forums anymore. Times and dates in your local timezone. Full tracking of what you have read so you can skip to your first unread post, easily see what has changed since you last logged in, and easily see what is new at a glance. Email notifications for threads you want to watch closely. Being a part of the oldest wargaming community on the net. If you are already a member then feel free to login now.

So I saw the sign in Joann fabrics saying 60% off upholstery foam and suddenly decided to make my own troop transports.

How the hell do you cut foam like that without it getting mangled? I tried a razor knife, but it still wound up with burrs and tufts all over the place. My plan was to cut a rectangle and glue it to a piece of craft foam the same size as a Battlefoam tray (so I can stack them with my existing ones). I was going to cut out spaces in the rectangular section for my models, but I don't know how to do that without getting ragged edges all over the place.

The only way I enjoyed success was to:

1. Get a thin paring knife with a very pointed tip. Sharpen it.
2. Sharpen it again.
3. Begin by cutting a small notch - small slices at a time - just to 'bite' into the material.
4. Once you cut through the material, 'saw' through it slowly, letting the (you did sharpen it, right?) very sharp blade do the work and applying little to no pressure on the foam (so as to avoid distorting it while you cut).
5. To change direction, you are best off beginning a new cut rather than trying to 'curve' the existing cut, unless your blade has a very low profile. Still, expect distortion in the foam. Squares are easiest to make, for sure.
6. Only once you have cut through the material should you glue on the bottom. I used hot glue and it worked great.

Good luck!

either get a blade so sharp it will cut you by just looking at it, or get a laser

 BewareOfTom wrote:
either get a blade so sharp it will cut you by just looking at it, or get a laser

Just to clarify, the laser thing was humor, yeah? That's totally not a piece of equipment I'd ever be able to afford, right?

Actually, you'd be suprised. You can get some pretty powerful lasers for a reasonable price.

Of course, mostly they'd just set the foam on fire unless you have the right power. And that's bad.

I use these:

http://www.amazon.com/Festool-493656-Foam-cutting-Jigsaw-3-pack/dp/B0033LBOJY

Back when I learned how to do upholstery - I was taught using an electric carving knife (works quite well too) - but the jig saw allows for tighter turns and what not.

Of course, if it is less than an inch thick - just compress it down to almost flat and slice through in a single go with a razor blade (takes a bit of practice - but fast and clean cuts).

We did this and in my honest opinion you should take your cutting implement and stab it in your leg. This will get you the end resulted pain in one hit rather then slowly beating your head against a foam wall till you pass out.

In summary cutting foam is a terrible experience.

Electric Knife, like grandpa uses at thanksgiving.
http://www.walmart.com/search/search-ng.do?search_query=elictric+knife&ic=16_0&Find=Find&search_constraint=4044
.
really, that is what to use.

I have made 3 footlocker sized cases. Electric carving knife is the best solution.

10" fishing filet knife, and a good quality whetstone. generally no sawing required.

If you don't want to build your own hot wire cutting table (the fumes are nasty) go with the electric knife thing, works well.