Cutting foam rubber

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Simpo Two

Original Poster:

85,363 posts

265 months

Thursday 28th July 2016
quotequote all
I need to improve some foam rubber cushions made for me by someone who claimed to be a professional upholsterer. Underneath the cover, this is what their work looks like. I've seen better primary school projects:



I also need to taper them so a long wire or blade would be ideal. Thanks!

DocJock

8,354 posts

240 months

Thursday 28th July 2016
quotequote all
If you can't source a hot-wire trimmer, an electric carving knife will do a reasonable job.

Edited by DocJock on Thursday 28th July 18:51

mgtony

4,019 posts

190 months

Thursday 28th July 2016
quotequote all
You could probably use an axe and it would improve the cut edges! hehe

It really is pi$$ poor considering each of those layers could easily have been cut one at a time to a decent standard just with a pair of scissors! irked

ndg

560 posts

237 months

Thursday 28th July 2016
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The proper tool is a scintilla saw, though that would be an expensive tool for a one off! It would be worth talking to a foam shop who might help you out.

crmcatee

5,694 posts

227 months

Thursday 28th July 2016
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Simpo Two said:
I've seen better primary school projects:
That's cruel to primary school projects.

Get an old bread knife and a plumbers torch (or stick it in a fire) - heat it up till it's hot and it will make mincemeat of that - easily slicing through them.

roofer

5,136 posts

211 months

Thursday 28th July 2016
quotequote all
DocJock said:
an electric carving knife will do a reasonable job.

Edited by DocJock on Thursday 28th July 18:51
This.

spikeyhead

17,300 posts

197 months

Friday 29th July 2016
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get it very wet and freeze it, you can then machine it in a lathe or mill

Simpo Two

Original Poster:

85,363 posts

265 months

Friday 29th July 2016
quotequote all
Interesting! Thanks all.

Is there any way to make my own hot wire device, say with a wooden handle and some judiciously applied electricity? The task above is the easy one, other cushions are up to 3' wide and need to be tapered in thickness.

s p a c e m a n

10,777 posts

148 months

Friday 29th July 2016
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You can pick up hot wires for £10 on fleabay, this is a bigger one though... http://www.ebay.co.uk/itm/311160893916

Simpo Two

Original Poster:

85,363 posts

265 months

Friday 29th July 2016
quotequote all
Thanks; I saw that - 16cm is just enough for the cushion above but can't see it tapering one 3' wide...

Andehh

7,108 posts

206 months

Friday 29th July 2016
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Steak knife or similar?

gareth_r

5,720 posts

237 months

Friday 29th July 2016
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Simpo Two said:
Interesting! Thanks all.

Is there any way to make my own hot wire device, say with a wooden handle and some judiciously applied electricity? The task above is the easy one, other cushions are up to 3' wide and need to be tapered in thickness.
Yes - search youtube. Guitar string/piano wire, 12 volt battery, wood.

An electric carving knife is surprisingly effective, though.

Saleen836

11,104 posts

209 months

Friday 29th July 2016
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Stanley knife should do a neat job, will cut through nicely when the foam is compressed

Tampon

4,637 posts

225 months

Friday 29th July 2016
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Simpo, who ever cut that used scissors, not a heinous choice but they did a crap job and the size looks off.

I take it it is a stool top with the wooden base? If so the layers of foam need to be stuck together before anything else happens, if they are then the outer edges need sticking down. (PM me if you need some glue I might have some still kicking about). Ideally that would have been made with solid foam not layers of one inch.

Did you ask for a progressive seat? the pinkish layers are very soft and the blue is firmer. More a composite sofa cushion than a stool pad.

As for cutting you can use scissors with layers of one inch. The main thing is they need to be half inch larger than what ever cover is going over/ finished size. It will also need a Dacron layer over the top to smooth the edge and give a professional finish (this is why the rough cut edge shouldn't make a difference as it will be compressed).

Don't cut them to size it will look a bag of bks when you cover them. Let me know what they are for/ post a pic and I can advise further.

Your friendly neighbourhood (ex) Upholsterer
Tamps



Simpo Two

Original Poster:

85,363 posts

265 months

Friday 29th July 2016
quotequote all
Tampon said:
I take it it is a stool top with the wooden base?
wavey They're cushions for a boat - 7 in total, all different shapes. They need to make a comfy bed. The layers are slightly stuck together and the layering may be because they are supposed to taper in thickness - except this one doesn't, doh! There was a thin bit of fluffy white stuff over the top. I took it apart because I could feel a big ridge, and the padding was such that the cushion wouldn't locate properly. The job really is shocking, and she called herself 'a proper upholsterer not a trimmer'. bks.

I shall be trying to get my deposit back and if I do, I'd welcome your quote because it needs to be done!