You can cut free-form shapes easily — just keep the foam moving at a smooth, constant speed.
You’ll notice that the slightest wiggle in your movements will result in a wavy or ridged part! Here are
a few tricks for easy cutting and perfect parts.
Make a guide from a piece of 1× 2 lumber and some ¼" dowels. Drill 2 holes on
1" centers and slip in pieces of dowel. Plug these dowel pins into the pegboard
and you’ve got an adjustable fence for smooth, straight cuts.
» Position the fence close to the wire to cut thin strips.
» Position the fence farther away to make wide cuts and to square up blocks.
» For size adjustments of less than 1", remove 1 of the dowel pins, and use just
1 pin as a pivot. Swivel the fence around the pin to adjust the angle until the
distance between the wire and the fence is just right. Place a second long
dowel pin behind the fence at the closest pegboard hole. Fast and easy!
Make a circle cutter guide out of a dowel and a nail. Cut a dowel to a length so
that when inserted into a pegboard hole, it’s flush with the tabletop. Drill a
pilot hole into the end of the dowel and insert a small nail — head first. Tap it in
with a hammer. Now you have a dowel with a pointy pin sticking out — be careful!
Place the dowel in any pegboard hole. The distance from the wire to the pin will
be the radius of your circular cut. Energize the wire. Slide a piece of foam into
the wire and impale the foam on the pin. As you spin the foam around on the
pin, you’ll cut a perfect circle. Turn off the wire and remove your part.
You’re not limited to 90° cuts. Build an elevated and angled wedge to make
beveled cuts! Make a wedge of the desired angle and nail it to a block with
dowels on the bottom.
Plug the wedge into the pegboard and slide the foam to make your angle cut!
For more super cool techniques for cutting hyperbolic, toroidal, and conic
shapes, as well as how to use templates, go to