Generic foam cutter

[kengore]

I have made my own cutters from strips of metal glues to a piece of wood scrap.

I used the metal strapping that is used to ship lumber, found all I needed in the trash pile at a nearby construction site. First I clamped a 20" long section to the edge of my work bench and created a sharp bevel edge using a metal file. Then I bent it to shape with needle nose pliers. I mounted the cutter to a piece of wood by setting it in a blob of 5 min. epoxy.

[flyangler]

kengore- you strapping young lad , have you had any problem with them popping out of the epoxy? Do you need to cut a groove of the proper shape into the wood first?

[kengore]

Fly Angler- I make a dam of masking tape around the perimeter and pour the epoxy about and 1/8" thick. Plenty of contact surface area, no need to cut a groove. Adding some epoxy filler (micro-ballons) adds bulk and helps self level.

I have also considered using single edge injector type razor blades for the cutter pieces...They tend to be brittle and often break on small radius bends, but I like how sharp they are.

[This message has been edited by kengore (edited 19 April 2006).]