Tool - Hotwire Cutter Outside Bench
The bench needs to be 16 feet long and ideally wants to have a waterproof roof to keep the rain off. You want it outside in order to have lots of ventilation as the fumes are nasty. It is made using two 8'x4' sheets of plywood. To set the sheet width to cut, you move a 16' long 2x4 that is chosen to be deliberately bowed. It is clamped at both ends and then 2x4 spacers of the desired length are put between it and the back fence to take out the bow.
The optional roof 2x6 beams need to be 22 foot long which you need to make using 16' lumber with 3' extensions at each end (with overlapping 6' pieces). The 16'x4' bench bed can be unbolted from the roof assembly.
Use a 12V 5A wall power adapter and some 24 gauge resistive wire.
Lots of good info is available at
http://jacobs-online.biz/index.htm
They have a useful
calculator at
http://www.jacobs-online.biz/nichrome/NichromeCalc.html
The image below shows my chosen settings...
The calculator shows that 10.7 amps is required, but the power brick only delivers 5A, so the temperature is not as hot as the calculator shows. It is still however enough for the wire to glow red hot. Do not touch the wire!
Here's what you will need...
Cutting wire
24 gauge 100ft spool
http://www.jacobs-online.biz/nichrome_wire.htm $10.50
Power wall adapter - 12V at 5 amps
http://www.amazon.com/gp/product/B00NPVHZIQ/ref=oh_aui_detailpage_o00_s00?ie=UTF8&psc=1 $8.98 free shipping
Electrical terminal turrets
http://www.amazon.com/URBEST%C2%AE-Female-Banana-Socket-Binding/dp/B00NWPGWP2/ref=pd_sim_sbs_e_2?ie=UTF8&refRID=0AKX3B9F9DR7Q4NK26NM $5.89 per pack.
Banana plugs
You need metal supports for the wire or else the wire will cut into the wood. The metal plates are fence brackets. They are held on with screws.
Wooden pieces
Use a wood clamp to push the top arm down slightly to get the wire fitted.
When using any hotwire cutter use it outside and arrange for a large fan to blow away the smelly fumes.