[gatrgof]

How are you guys cutting foam? I did it years ago hooking up nichrome wire directly into a 110 socket. Man did it cut fast!! When it got hot it grew 2 feet longer, scared the crap out of me, and it would hum as well, dangerous to say the least. I made a wood handle for the wires and a plywood form as well. Gotta be a better way as I will not try that again!!

[gatrgof]

I used a welder for a transformer and cut out some fuselage for a build. I will try a 12 volt battery charger next for power as I want to use a thinner wire .020".

[fhhuber]

Nichrome wire intended to replace a dryer heating element.
12 V battery
Alligator clip to adjust temperature by selecting where on the wire to clip on. (excess wire wrapped on dowels near the handle of the cutting bow)

Don't use the charger without a battery as a "buffer"
The charger will surge voltage and you get a sawtooth effect to the cut.

The smoother the pattern you are using the better the cut will be.
The better you are at moving the bow evenly the better your cut will be.

For a tapered wing you can find the point where extending the LE and TE out will meet. Anchor a wire (unheated) there and attach the cutting wire 3 inches from the wingtip.
You now only need a root rib.
Pre-cut the angle for the LE meeting the root then attach the root pattern.
Start the cut at the LE

[gatrgof]

I never thought of using the battery as a buffer, great point.