There’s many different reasons why somebody might have to hack together their own solution to a problem. It could be to save money, or to save time. Occasionally it’s because the problem is unique enough that there might not be an accepted solution, so you’re on your own to create one. We think the situation that [Raph] recently found himself in was a combination of several of these aspects, which makes his success all the sweeter.
The problem? [Raph] had a pair of foam mattresses from his camper van that needed to be made thinner — each of the three inch (7.62 cm) pieces of foam needed to have one inch (2.5 cm) shaved off as neatly and evenly as possible. Trying to pull that off over the length of a mattress with any kind of manual tools was obviously a no-go, so he built a low-rider foam cutter.
With the mattresses laying on the ground, the idea was to have the cutter simply roll across them. The cutter uses a 45″ (115 cm) long 14 AWG nichrome wire that’s held in tension with a tension arm and bungee cords, which is juiced up with a Volteq HY2050EX 50 V 20 A variable DC power supply. [Raph] determined the current experimentally: the wire failed at 20 A, and cutting speed was too low at 12 A. In the end, 15 A seemed to be the sweet spot.
The actual cutting process was quite slow, with [Raph] finding that the best he could do was about 1/8″ (3 mm) per second on the wider of the two mattresses. While the result was a nice flat cut, he does note that at s ..
Support the originator by clicking the read the rest link below.
