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Anyone know of a jig or punch that can make this style of popper consistently? Fillet knife results in various sizes and not the kind of work that I would like to put out.
http://smallmouthflyangler.com/site/...ducts/fl_f.php
http://flybass.com/html/foam_popper.html
check out the balsa popper jig in the link in my blog and adapt as required
http://www.flyanglersonline.com/bb/blog.php?b=230
why would you need a jig to cut foam into a popper body shown in your second link??
lets start with a 1/2 x 1/2 x 6 inch long block of foam.
1. cut to desired length
2. cut to desired shape
http://img.photobucket.com/albums/v2...popperbody.jpg
3. continue cutting until you have the quantity you need
Clay,
First, cut foam with razor blades. Any kind of knife will give you ragged results. In your second link they talked about a band saw??? Not a method I'd advise. I'm not all that picky, but the marks on the sides of those bodies look awful to me.
You can get a small metal or plastic 'hobby' miter box at most craft, hobby, or model making shops, as well as many hardware stores. They aren't expensive. Mine has 22 1/2, 45, and 90 degree cutting angles in it. This will give you accurate cuts for your angles.
For those clunky block type heads, all you need is the miter box and foam in the size you want...as Normand pointed out, if you start with a strip of the correct width/depth, you can cut to length and then add the angle with two cuts per body.
Use sharp blades and cut all the way through the foam on the first pass. You can get fishable bodies without any further work...if you like them smoother, you can sand this stuff with 300 to 1500 grit abrasive sheets (another easy to get hardware store item).
There are lots of different ways to come up with foam popper bodies...you can go really low tech, like the block types or the simple cylinders...or you can go with a turned body, hand carved ones, whichever you want.
Buddy
I shape mine on a disc sander...square it up...do the back taper, do the side tapers. Cheers.