Construct the Hot Wire Foam Cutter. Needed Parts. Junctio

1
Construct the Hot Wire Foam Cutter
2
Needed Parts

• Junction box
• UL-approved 16/3 cord with grounded plug
• Outlet
• Dimmer switch
• 6/12V battery charger with 6A output
• Wire
• Hardware
• 5/8 particle board

3
Guidelines

• Only people experienced in shop safety practices
  should attempt this procedure.
• Take precautions to ensure the completed project
  is safe for use.

4
Procedure

• Mount outlet and dimmer switch to top of junction
  box.
• Install strain relief clamp onto junction box and
  route cord leads into box.

5
Procedure

• 3. Connect leads as followssplice cord white to
  lead from dimmer, cord black to terminal on side
  of outlet labeled black, cord green to gnd
  terminal on outlet.
• Connect remaining dimmer lead to terminal on
  side of outlet labeled white
• Connect gnd lead between dimmer gnd and outlet
  gnd.
• 4. Assemble box.

6
Procedure

• Use 5/8 particle board for wire mount. Base is
  7 x 12. Crosspiece is 3-1/4 X 12. Sides are
  cut from rectangles 7 x 12. Cut tops of sides
  as shown (curve starts 4-1/4 from bottom edge).
• Route sides for crosspiece, top of route 3-1/4
  from top of side. Route base for sides. All
  routes ¼ deep. Glue crosspiece and sides into
  routed slots.

Route forcrosspiece
Route for sides
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Procedure

• 6. Drill holes to allow 2 clearance between wire
  and crosspiece. Single bolt held in place with
  nuts, has hole through shaft to insert wire
  through, wire then wrapped around shaft. Opposite
  bolt has hole length of shaft, wire fed through
  shaft, out head, wrapped around screw mounted
  below bolt.

2
8
Procedure

• 7. Attach clamps from battery charger to
  screw/terminals on wire cutter as shown. Use 6V,
  6A settings on charger, rotate dimmer to read 4A
  on meter.

Plug charger into control box.