Here are some pics of my Hot Wire setup.
Had built this some time ago.
My camera was on lease, so couldnt log the build.

However have tried for a fair reconstruction.
Hope this is helpful.

01: Hot wire ckt.

24v 4A Transfomer
Dimmer Switch (Fan regulator without step). - around Rs.100/-
Old empty Power Supply box. Got from a local electronic repair shop. - for Rs.100/-
4 banana socket and plug.
Nichrome wire


B3, B4 with S2 close - B3, B4 takes the actual Hot Wire Load
B1, B2 with S2 open - dummy load connected across B1, B2. B3, B4 takes the actual Hot Wire Load (very small length - see 'Pastry Knife' below)

Cost of Transformer = Rs.750/- (ofcourse you get lesser quality ones starting from Rs.350/-)

04, 05: Top View of the Power Supply box modified to a Hot Wire PS.
06: Front View, Notice the Dimmer. S1,S2, D1 are already available.

07: Hooks, Curtain spring and Curtain spring hooks.
08: Setup view - simple and easy to get parts.
09: Hook attached to the end of 1-1/4th inch Cane rod

10: setup with supply wire.
11: Complete view of Cane Bow Hot wire cutter. (30" Bow)
12: A small bow that I build out of an old mini hacksaw frame. I call this 'bevel cutter'.
It cuts as easy as your 'Pastry knife'.

13: Sample foam for bevel cutting.
14: Step1: Scale attached to sample piece using cello tape;
15: Step2: Another scale at other side at a distance equal to the thickness of the sample sheet. This creates aperfect 45deg bevel.

16,17: Step3: Pastry Knife setup.
18: There you go, A fine and perfect bevel.

19: My Cane bows - 50", 30", 6".
20: Table template cutter in progress.

21: My Cane bow run on a old block.
22: Sample wing cut to test my 30" Cane Bow. Used a +ve template cut out of 1mm laminate sheet.

great going , one of he most useful thread i found on our forum

Thanks Augustine..

Okay here is a video of me and RC perfecting the art of Foam cutting.

[http://www.youtube.com/watch?v=dOOZFlBpa9o]

Cool, since I switched the company, Iam missing all the serious stuff you guys are doing BIG TIME! 

Will be back in action soon! 

  wow really helpful specially the part that you attach scales to make the bevel. Thanks so much.

can i use the same technique to get something out of my 18v / 1.5 amp  transformer or  12v 1amp transformer ?

Depends on
1. Length of the wire.
2. Material of the wire.

There are lot of ppl on this forum who have been able to do this at 1A/2A.
You could use music wire.
On my setup(24v/4A) music wire yields.

hey nice video... is that cardboard on the side???

Its 1mm laminate sheet. The one used on furniture; esp cupboards & table.
Name is Sunmica/Formica.
Stuck using double sided tape.
Have tried with ply/veneer but they burn and make tiny notches on the top.
The notch give a bad contour on subsequent usage.

Wow!!! this is fantastic Drone!! I missed this one!!
I just love the Cutting Table you have!! and using Cane for the bow! nice.
I have one doubt in your Power supply Ckt diagram. The LED should not be in 'Series' of one line. It should be parallel to the line after the dimmer. Or you have a Low res/High Watt Resistor in series, with the LED connected to its either end?

That's a nice build, I love the way you have indeginisation it by using cane bows.

Have you used nichrome wire, where it's available in Bangalore.

Thanks Akshay. You can get Nichrome wire for foam cutting from Raju - EPPIndia.

Thanks for your reply, but while it came I found out a good source of Nichrome wire, so in future if you need any, feel free to contact me.

What thickness of wire have you used.

I am in process of making a HWFC and probably, should be completing it this week end.

And shall be looking to cut some good wings.

Mine is a simple setup with Guitar Steel E string, 12 V, 9 Amps (computer ATX power supply), on a simple bent bamboo bow.