Need help with styrofoam insert cutting

[Pixelboy]

Hello good people!

 

Last year, I had around 2000 styrofoam inserts manufactured, and I plan to use them for my upcoming ColecoVision homebrew releases. A small portion of these inserts were incorrectly cut and wound up being too thick to be used in my Team Pixelboy boxes.

 

I've been looking for an alternative use for these thick inserts, and I found one: As a side project earlier this year, I had a set of 100 custom boxes prepared and printed for AtariAge. They will be used for the re-release of Daniel Bienvenu's Jeepers Creepers (published by AtariAge).

 

The Jeepers Creepers boxes are the exact same dimensions as my Team Pixelboy boxes, so the thick inserts don't fit in them. However, if I can find someone equiped with some kind of tall saw that could cut them in two, Albert would be more than willing to use them in the Jeepers Creepers boxes, especially since I'd be giving them to Albert for free.

 

A picture is worth a thousand words, so I attached a picture below that describes what needs to be done. The inserts are 6.25 inches tall. If you have access to cutting equipment and can perform this job in a precise, clean and professional way, please send me a PM.

 

Ideally, I will send 50 thick inserts to whoever volunteers for this little job, and once these 50 inserts have been split into 100 thinner inserts, they will be shipped directly to Albert. I'll pay for all shipping charges.

 

Thanks in advance for any assistance.

 

EDIT: Since I'm in Canada and Albert lives in the USA, we would prefer to have someone living somewhere in North America perform this little job.

Edited December 11, 2010 by Pixelboy

[Yurkie]

I think that turning them on the side and starting the cut from the bottom would probably work better. I would suggest a band saw. I don't know how they would turn out as far as tool marks and chipping. If they the softer spongy type of foam, results might be pretty good. If I were still working in a machine shop I would be happy to do these for you.

[+evg2000]

I know noting about them, but I know there are electric foam cutting knives for hobbies. this is one example:

$15 foam electric foam cutting knife

[Pixelboy]

I think that turning them on the side and starting the cut from the bottom would probably work better. I would suggest a band saw.

Yeah, something like that. The inserts are 5 inches wide, if anyone wants to know.

 

I don't know how they would turn out as far as tool marks and chipping. If they the softer spongy type of foam, results might be pretty good. If I were still working in a machine shop I would be happy to do these for you.

Thanks for almost offering to help.

[Pixelboy]

I know noting about them, but I know there are electric foam cutting knives for hobbies. this is one example:

$15 foam electric foam cutting knife

It could possibly work, except that it would be hard to do a straight, clean cut...

[Yurkie]

I know noting about them, but I know there are electric foam cutting knives for hobbies. this is one example:

$15 foam electric foam cutting knife

It could possibly work, except that it would be hard to do a straight, clean cut...

 

It's too bad the blade isn't longer, if it where I don't think it would be difficult to make a fixture to mount it horizontal to a table top and run them through lying flat.

 

Perhaps a wire connected to a soldering iron. I am tempted to hit the hardware store and starting rigging.

[+evg2000]

That was just the first one I found, there are instructions for creating them I believe you just need a wire and a power source, so you could create a custom rig.

MAKE mag foam cutter

foam cutter

foam cutter

[Yurkie]

Those look like a lot more work than necessary. I think 2 bolts sticking up through a smooth flat piece of plywood spaced about 6" a part with ceramic insulators (prevent heat from dissipating) at the top. The height would be adjustable using nuts and washers. Draw the wire tight, smooth and straight between these and wrap the wire around a soldering iron at each end. The wire would get crazy hot and should cut through like a knife through butter.

[Chuck D. Head]

I know noting about them, but I know there are electric foam cutting knives for hobbies. this is one example:

$15 foam electric foam cutting knife

It could possibly work, except that it would be hard to do a straight, clean cut...

You could make two pieces of 1/4 plywood or similar with the proper profile to use as a guide, place several foam pieces in between in sandwich fashion (total thickness equal to the length of the wire on the cutter or smaller) and secure the "sandwich" with clamps or even packing tape. Then, using the plywood as a guide, use the hot wire knife to make the cuts.

[Pixelboy]

Look guys, these DIY solutions sound nice, but I have absolutely no time to get the required parts and perform the operation myself.

 

Perhaps I should just contact the company that sold me those inserts in the first place. They can surely help, although I'm pretty sure they will soon be shutting down all operations for the Holidays, so it will have to wait until January.