Thread: cutting foam sandwich

Cutting with a router would be the best way to avoid chipping the outer skin. This is how the manufacturers do it. If you use a circular saw you may have success by using a sacrificial board between the sheet and the machine to give the outer skin support when the saw tooth breaks through.

Originally Posted by Killer

Cutting with a router would be the best way to avoid chipping the outer skin. This is how the manufacturers do it. If you use a circular saw you may have success by using a sacrificial board between the sheet and the machine to give the outer skin support when the saw tooth breaks through.

A router .... Now that is something I would never have thought to use. Thanks! I'll give it a try

Ordinary steel blade will dull quickly on fibreglass and will chip, even fine toothed blades. Diamond wheel for an angle grinder cuts fibreglass nicely with no chips and the foam should be no problem. I'd cut from both sides instead of doing it in one and drill the corners to transfer reference. If money is no object, get a diamond wheel for a circular saw. You can also get diamond edged blades for reciprocating saws if you want to cut from one side. Just take it easy and should not chip.

Originally Posted by Max Headroom 2.3m

Ordinary steel blade will dull quickly on fibreglass and will chip, even fine toothed blades. Diamond wheel for an angle grinder cuts fibreglass nicely with no chips and the foam should be no problem. I'd cut from both sides instead of doing it in one and drill the corners to transfer reference. If money is no object, get a diamond wheel for a circular saw. You can also get diamond edged blades for reciprocating saws if you want to cut from one side. Just take it easy and should not chip.

Hmmm... I've always wanted to try one of those diamond saw blades ...

the diamond saw blades work well.

use a cordless grinder keep it in a bag and keep the work wet.

as per other comments, corner drill, line mark, all the other good cutting thick stuff info.

AND..

use the double glaze windows if you can get them, or use 2 outer window shells and do your own double glaze.

If you dont,, get the windows with the screen adjacent to the window then you can use the bottom edge as a shelf for pen organizers and the like... (depending on where you put your windows)

Dont forget to get some good sealer on the foam before you put the windows in. Keeps bugs, rodents and moisture at bay.

Originally Posted by Blknight.aus

the diamond saw blades work well.

use a cordless grinder keep it in a bag and keep the work wet.

as per other comments, corner drill, line mark, all the other good cutting thick stuff info.

AND..

use the double glaze windows if you can get them, or use 2 outer window shells and do your own double glaze.

If you dont,, get the windows with the screen adjacent to the window then you can use the bottom edge as a shelf for pen organizers and the like... (depending on where you put your windows)

Dont forget to get some good sealer on the foam before you put the windows in. Keeps bugs, rodents and moisture at bay.

Amazing, yes I have a crappy ozito cordless grinder here (they are quite gutless.... but very safe due to this). So I'll grab a diamond blade and see how I go!