I've read what I could find on cutting foam for the Zenith seats (in particular, the XL). Maybe I looked in the wrong places, but I found a lot of good information on the construction detail of the seats, but not much on how to actually cut the foam.

I decided to try a method I'd heard of some years ago. It worked to my satisfaction, but describing it is a bit long for this website, so I have posted the details of the tool I build to cut foam here:

http://anemicaardvark.com/Zenith/CuttingFoam/

Views: 770

Reply to This

Replies to This Discussion

Good info!  Thanks for sharing.

I did the initial shaping on mine with a serated bread knife.  It worked to my satisfaction.

Hi Jim

Just on a OH&S note,please remember that the gases produced from cutting foams with a hot wire are highly toxic. I did not see this mentioned in the article.

I used my bandsaw with a std coarse wood cutting blade with great results. This is the same blade that I use to cut all of my 6061-T6.

 

Regards

Phill

I did some research on Confor Foam producing toxic gas, but I haven't found any references on this. My understanding is that it is based on polyurethane, with additives. Lacking more detailed information, I can't really discuss this one pro or con. If you have a reference, it might be worth posting and incorporating.

I do have a statement of compliance with FAR 25.853(a) (1)(ii), which is says the material resists flamabilty. That's nice, but it doesn't really say what happens when someone intentionally heats it as I did.

My overall conclusion is that this fits in the same general category as a lot of aircraft chemicals and the like: if you don't know of a certainty that something is benign, a well ventilated area and protective clothing is a good idea.

An electric knife works perfectly. That is, as long as your wife doesn't find out. ;>)

There have been several comments about various cutting instruments working well with the foam. If it worked for you - great! I haven't had any luck with any cutting technique available to me doing much more than tearing the foam.That drove me to the hot wire cutter, a method I knew worked for me.

My advice to anyone trying any method of cutting the foam would be to try the tools you have that seem reasonable, rather than buy or build something else. If they don't work, try the methods outlined on this forum, and use the one that works best for you.

My wife can somehow find out when I have diverted things like electric knives to use as an aircraft tool. It may simply be that we've been married long enough that she knows my tricks.

OregonAero who charges big time for their confor foam seats, military headsets, etc.  has nothing but 8 grizzly 14 inch bandsaws to cut their foam.  Some people use turkey electric knives, which I have used as well as a good sharp knife and a band saw.  It is all in the operator.  no special tricks etc.  besides that, if you put the scrimback foam on the covering, and roughness will not be apparent.  There is a very good series of articles, May, June,2010 that are well worth the 20 bucks subscription to Kitplanes.  These articles will save you much time and give you a better result.  I know since I have spent many hours researching and bought books, these give you the most for your money. 

RSS

New from Zenith:

Zenith Planes For Sale 
 

Classified listing for buying or selling your Zenith building or flying related stuff...


Custom Instrument Panels
for your Zenith
:

Custom instrument panels are now available directly from Zenith Aircraft Company exclusively for Zenith builders and owners. Pre-cut panel, Dynon and Garmin avionics, and more.


Zenith Homecoming Tee:


Zenair Floats


Flying On Your Own Wings:
A Complete Guide to Understanding Light Airplane Design, by Chris Heintz


Builder & Pilot Supplies:

Aircraft Insurance:

 
 

West Coast USA:

 
Pro Builder Assistance:

 

Transition training:

Lavion Aero

K&S Aviation Services

Aircraft Spruce & Specialty for all your building and pilot supplies!

How to videos from HomebuiltHELP.com

Developed specifically for Zenith builders (by a builder) these videos on DVD are a great help in building your own kit plane by providing practical hands-on construction information. Visit HomebuiltHelp.com for the latest DVD titles.

© 2024   Created by Zenith.Aero.   Powered by

Badges  |  Report an Issue  |  Terms of Service