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What is the most accurate way to cut 2 inch foam?

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  • Member since
    November 2019
  • 207 posts
Posted by The Milwaukee Road Warrior on Friday, January 1, 2021 10:30 AM

Henry, I don't know if its the BEST way, but the only way I've ever done this is using a jig saw.  I had the same thing happen with small areas of foam overlapping.  I didn't get any special kind of blade, I just used the same blade I was cutting plywood with, and I carefully ran along the edge.  It worked fine for me but I don't know how wide your tolerance is.  

In some of the larger overlaps I glued the entire sheet down, then measured in from the edge of the foam to the edge of the benchwork on the underside and transferred that to the top side in enough places that I could draw an accurate line to cut along.  It worked pretty good overall.  I will have some small areas to fill in later.

Andy

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Milwaukee native modeling the Milwaukee Road in 1950's Milwaukee.

  • Member since
    December 2015
  • From: Shenandoah Valley
  • 7,662 posts
Posted by BigDaddy on Sunday, January 10, 2021 8:11 AM

Follow up:    I got the Bosch blades.  6" was all I could find.  It has rounded serrations and they wanted to grab the foam and bounce it up and down.  That's easily overcome by putting more pressure on the jig saw, but my B&D jig saw would tilt from being perpendicular. 

The cut was as smooth as it could be and no dust at all.

Henry

COB Potomac & Northern

Shenandoah Valley

  • Member since
    November 2019
  • 207 posts
Posted by The Milwaukee Road Warrior on Sunday, January 10, 2021 9:22 AM

I failed to mention that in my case I had already glued down my sheets to my plywood benchwork, so when it came time to cut with the jig saw nothing moved or bounced around.  That may not be practical for others depending on how/where they plan to use the foam: they may have to cut first and glue later.

Andy

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Milwaukee native modeling the Milwaukee Road in 1950's Milwaukee.

  • Member since
    December 2017
  • From: Just outside of Leitchfield, Ky
  • 102 posts
Posted by mrrdad on Sunday, January 10, 2021 12:52 PM

Not that this is practical for what the OP is trying to do, but I've had good success cutting it with a fine tooth blade on a table saw

 

Ed

Semi newbie HO scale modeler coming from the O scale world

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