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1. 

   David Arken

   11 Kudos

   07/09/08

   Our local HD does not have anything except beer cooler foam, what is the specific material yours has?
   
   All you need for the hot wire is a bow you can make and a dc voltage source like a varac (spelling??).
   
   make the bow like an H with pivots at the intersections, pull the wire across one open end of the H and use cable with a turn buckle on the other so the wire can be tensioned.
   David
   Original comment »

   07/10/08

   Reply from pleonard2000:

   I think I might have gotten my last piece at Lowe's .. but I remember seeing it at Home Depot also.
   They come in 2'x8' panels, 1" thick.
   It's labeled as Styrofoam extruded polystyrene insulation - tongue and groove.
   Like this;
   http://building.dow.com/styrofoam/na/pro-us/products/styrofoam/index.htm
   
   It has a nice, tight construction ... cuts would be fairly smooth and not full of air holes.

2. 

   David Arken

   11 Kudos

   07/09/08

   Getting the foam is the most difficult part of foam cutting. When you make a pattern , formica works well and polish the edges to help the wire slide better. We use 0.032 stainless safety wire.
   David

   07/09/08

   Reply from pleonard2000:

   Thanks for the input.
   I can't find any commercially available wands that can handle a 61" span ... I might have to make my own.
   I was just planning to use the blue foam sold at Home Depot ...

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