I bought a new IceCastle and want to put 2" faom inbetween the frame rails. I bought the hd foam but was wondering the best way to sut the stuff is? I don't want it too rough and it is going to be press fir with a little adheasive in the corners.

Table saw works great, but is a little messy with the dust. Do it outside if you can.

A hot wire setup will give a very nice finish, but is probably much more difficult to come by.

Travis

A sawsall will work as well.

handsaw

Just got done cutting 2" foam on a table saw. It worked very well cutting it one way (width) but cutting the long way it got a little bucky. We were just using a normal wood cutting blade. You may be able to find something that would work better.

Wonder cutter's are sold in most craft stores and are used to cut styrofoam. There is a 2 "D" Battery model that will cut up to 2 inch foam and there is a wall plug-in model that will cut up to 4 inch foam.

I use one of these to cut tombstones out of that pink foamboard a few years ago and it was very easy to use and left nice smooth edges. Not the fastest method to cutting foam but definately the method for the cleanest edges.

If speed over neatness is your preference, then either go with the handsaw or use a hand jigsaw.

Just my two cents
Redbeard5289

Not sure what to call it, like a cheap utility knife that has a 4"-6" segmented blade and you can snap some off when the end is dull. Hardware-home stores will have them. One of those and a straight edge of some sort will get the job done fast and cheap. May not be a perfect cut but good enough.

You can make a hot wire cutter pretty easy.

Here is one schematic that I found.

It uses a doorbell transformer, a dimmer switch and other items that can be easily found.




Don't try this at home unless you know what you are doing though.

Straight edge? Razor knife and snap it off, just like drywall. Curves, got no idea.

I have used a knife blade in a jig saw in the past, worked well.

THe fun way - put a 16 penny nail in a vice grip, heat it with a torch until red, then slide it through foam. Very quick cutting, no mess, but it can get stinky - use ventilation. This is more for "carving" the foam than cutting it, but works great... and fun

With a table saw I've had the best luck running it through the saw from the opposite side you normally do (in through the outfeed side of the table). Otherwise score it with a utility knife and snap it.

I used an electric knife from the kitchen and it worked fine for me. It's a good thing my wife was at work. It still carves a turkey great also.

Table saw works good. It will be messy as mentioned though.

I like a chainsaw

Depending on what I'm doing, a jigsaw works pretty good. Otherwise the table saw does a good job.