Cutter Designs
Cutter Designs
Horizontal Cutter
1x - C-33 Utility Extension Spring
2x - #10-24 3 1/2” Thumb Screw Bolt
4x - #10 Washers
2x - #10-24 Wing Nuts
2x - #10-24 Tee-Nut Fastener
- Available as “Long Prong” or “Brad Nail”
NiChrome Wire
26 gauge - Approximately 12-16”
Optional Components
2x - #8-10 14-16 AWG Ring Terminals
1x - Figure-8 Ring
The NiChrome wire will span two thumb screws that are mounted into two Tee-Nut Fasteners. An extension spring is a must, but you may decide to use a Figure-of-8 eye hook or an additional washer for attachment.
You’ll want to select a region on the cutter that is furthest out to the sides to maximize your cutting width. Also, make sure you drill the pilot holes through all underlying wood to ensure free passage of the thumb screws.
Basic design pictured here, giving you a rough idea of wire attachment
Consider attaching the connection wires to the wooden supports to help prevent tangling, accidental damage or detachment.
With most of the other cutters, you typically hardwire electrical connectors. But due to the temporary nature of this cutter it is suggested to choose a more simple option.
In comparison to some of the other components on this website, I attempted to not over think this cutter. By using less components (hex screws, washers, etc) you can maximize the range of heights by which you can cut your foam.
You may not want to use the figure-of-8 eye hook to maximize your cutting width by using an extra washer instead.
You may also notice that the electrical attachments are not pictured. There is no one right or wrong way to achieve electrical attachment, as you may find that alligator clips work better for your rather than crimp-on ring terminals.
Thumb Screw Assemblies
TeeNut Fastener Assembly
Parts List
Sequencing Diagram
PDF available for download
Listed herein are the visual and printable schematics for your own
Horizontal Table Top Hot Wire Foam Cutter
This particular design is more of an addition than it is a stand alone cutter. You may opt to place this horizontal cutter on any surface you desire, but it is suggested to add it to an existing vertical table top cutter.
The horizontal components are meant to be temporary and removable at any time. This will allow you to continue to use your table top cutter as a vertical cutter without the horizontal cutter components getting in the way
Using Tee-Nut Fasteners (pictured below) you are able to achieve the temporary nature of this cutter.
Reference the Vertical Table Top Design for additional information regarding structural design and assembly.
Structural Components
Electrical Components
Personally, I like the Crimp-on Snap Connectors the best. You simply have to place one snap connector on each lead wire and you’re set. Because they’re insulated you don’t have to worry about accidental short circuits as you would with alligator clips..!
Personally I find that using an additional washer, instead of an eye hook will maximize the cutting width of your NiChrome.
There are two main types of TeeNut Fasteners : “Brad Nail” and “Long Prong”
Functionally there is no difference between these two fasteners, but only differ in how they attach to your cutting surface. While the Long Prong is easier to install, it requires more overall force when imbedding the prongs into the cutting surface. So for cutters that are a bit smaller and more delicate, you may opt for the Brad Nail fastener instead.
To best explain these fasteners, you should watch the tutorial video for the horizontal cutter.
This is the attachment sequence on the cutter from the tutorial video. You’ll notice that the top most washer has the nichrome attached to it in lieu of the figure-of-8 connector. Also, there is a ring terminal and hex nut screw at the top.
The only reason one might not choose the additional hex nut at the top is that it may add additional bulk and/or reduce the range of vertical heights achieved by the horizontal cutter. But for the most part, neither of these potential problems are really a big problem. Just personal preference...