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Cutting Foam Rubber ??

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Rich

09-20-2001 19:16:47




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Picked up sheet of 10" thick foam rubber to make seat cushions with. Any tips on how to cut foam rubber using plywood seat bottom and back for template ? Utility knive, straight razor ???




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Lloyd Smith

09-21-2001 19:08:23




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 Re: Cutting Foam Rubber ?? in reply to Rich, 09-20-2001 19:16:47  
An electric carving knife works well



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Kevin

09-23-2001 15:58:18




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 Re: Re: Cutting Foam Rubber ?? in reply to Lloyd Smith, 09-21-2001 19:08:23  
Yep, electric knive for main, then an olfa for the final clean trim!



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Farmer/Paul

09-21-2001 16:51:51




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 Re: Cutting Foam Rubber ?? in reply to Rich, 09-20-2001 19:16:47  
I worked in the auto seating industry for a few years,when repairing cushions we cut the foam with butcher knives or the Olaf razors/ with a retractable blade. I wouid not recommend using the hot wire method as the foam is made with TDI (Toluene Disocynate). The burning foam creates a form of cyanide gas. When we had fires in the curing oven used to produce the foam, Scott air pacs had to be used to proteect us from the toxic smoke.

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bob

09-21-2001 07:46:20




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 Re: Cutting Foam Rubber ?? in reply to Rich, 09-20-2001 19:16:47  
I used a cheap (~$10) electric knife to cut up a bunch of foam rubber for seat cushions for a 29' sail boat I built a few years back. Had no problems making straight, curved and coompound curve cuts.

Another boat builder made a "hot wire" knife by stretching a length of wire (probably the stuiff you use to repair heating coils) between a couple of insulators and connecting it to the power line. Be very careful if you chose to use this technique as you are exposed to live electric wiring.

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big fred

09-21-2001 07:45:14




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 Re: Cutting Foam Rubber ?? in reply to Rich, 09-20-2001 19:16:47  
Wow, 10 inches thick! I think I used two layers of 3 inch foam for the seat on my IH 300 Utility. I cut it with my table saw using a combination blade. Worked very well and made a really neat noise while it was cutting.



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Tyler(WA)

09-21-2001 07:12:59




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 Re: Cutting Foam Rubber ?? in reply to Rich, 09-20-2001 19:16:47  
My Dad is somewhat of an aritst and decided to make some starfish out of foam rubber. That's some tricky carving on something that wouldn't sit still (like trying to give 4 yr. old a haircut.)

It turned out so well with such detail that I had to ask him how he did it.

"Easy, I soaked it in water and froze it." The water held the foam and then it was easy to work with any tool, even a file.

Once it's the shape you want, let it thaw out and dry. Presto! Perfect seat with rounded corners and all.

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F14

09-21-2001 03:40:16




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 Re: Cutting Foam Rubber ?? in reply to Rich, 09-20-2001 19:16:47  
I use my band saw with a coarse blade. Works slick as a smelt. Trace around the seat bottom with a permanent marker to get the outline.



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John Garner

09-20-2001 19:27:33




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 Re: Cutting Foam Rubber ?? in reply to Rich, 09-20-2001 19:16:47  
Rich --

Do you have an electric carving knife? (You know, the kind that some people use for their Thanksgiving turkey . . .) These use a pair of counter-reciprocating blades -- one slides in while the other slides out -- and they work like a dream for cutting foam rubber.

I'm not sure, but I think that the "electric fillet knife" that Wal-Mart sells in their sporting goods department is essentially the same thing and would probably work as well.

John

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