Looking for tool between one-handed recip & electric carving knife

[DMucci]

I make custom seats for the motorcycles I build and the foam I need to shape can be pretty high density. I've burned out my share of electric carving knives and the one-handed recip saws I've seen from the big brands (bosch, dewalt, rigid etc) are just too bulky for detailed shaping.

Basically I'm looking for a tool that's between these:

- Powerful enough to cut through foam...plastic...wood etc
- Nimble like an electric carver

 

[ocloc24]

Air recip saw?

Random pic for size reference

 

[DMucci]

Good body size but the air lines are usually a pain in the *** to maneuver with. I also need it to have a 6"-8" blade length.

 

[JimNC]

Have you considered cutting it with a hot wire?

 

[DMucci]

Have you considered cutting it with a hot wire?

I'm not sure that'd work with the high density stuff. It's the "fruit cake" style foam, like this:

 

[dogdog]

Not sure your definition of bulky... I have one of these, it's ok, smaller than a sawzall but not sure if it is smaller than the Milwaukee thing that you pictured. But it does look like the hybrid of what you are saying.

http://www.searshardwarestores.com/...nyAra0mw0qvKMGrPZibGRgb_DkueI9iAaAvCQEALw_wcB

 

[DMucci]

Not sure your definition of bulky... I have one of these, it's ok, smaller than a sawzall but not sure if it is smaller than the Milwaukee thing that you pictured. But it does look like the hybrid of what you are saying.

That thing corded would be perfect. That's pictured without the battery right? I'll have to go look at one in person.

 

[DMucci]

Found an image of this but can't find it for sale anywhere:

"Model 3315"

 

[thickhead]

https://www.ingersollrandproducts.c...01.html?cid=pr_med_irp_pt_cn:RecipSaw_co:PPR_

http://www.eastwood.com/eastwood-electric-body-saw.html

https://www.homedepot.com/p/RIDGID-THRU-COOL-6-Amp-1-Handed-Orbital-Reciprocating-Saw-Kit-R3031/100646504

https://www.harborfreight.com/electric-body-saw-65766.html

 

[bcradio]

Found an image of this but can't find it for sale anywhere:

"Model 3315"

Look for the Ridgid version then

 

[DMucci]

Picked up a few of the Rigid & Ingersol versions and they're still pretty massive. It'd be like trying to sculpt with a dumbbell.

I guess I'm looking for more of an industrial strength electric knife. The one's I've burnt up were 100-120W. If I could find something around 200W that may be enough.

Looks like most electric carving knives don't go over 150W. Maybe something for gardening or commercial grade kitchen stuff?

 

[bcradio]

Ridgid will be the same size as the craftsman, so craftsman will be too big as well.

 

[PugetDude]

Look for a used Makita 4390D 9.6 volt reciprocating saw. Plenty of power for foam, lightweight, batteries still available.

https://www.ebay.com/itm/Makita-439...677577?hash=item36249faa49:g:GOkAAOSw5ShZyB8x


https://www.ebay.com/itm/Makita-Cor...242145?hash=item41d2f677e1:g:nK8AAOSwH-dZ9Qdl

 

[PugetDude]

Looks like Speedway offers a compact corded saw:

https://www.ebay.com/i/131626423295?chn=ps&dispItem=1

EDIT $25 at Home Depot Online- might be worth a try.

 

[shawndp]

Maybe a 12v electric saw? I have a Dewalt and the M12 Hackzall and both aren't terribly heavy

 

[DMucci]

Look for a used Makita 4390D 9.6 volt reciprocating saw. Plenty of power for foam, lightweight, batteries still available.

https://www.ebay.com/itm/Makita-439...677577?hash=item36249faa49:g:GOkAAOSw5ShZyB8x


https://www.ebay.com/itm/Makita-Cor...242145?hash=item41d2f677e1:g:nK8AAOSwH-dZ9Qdl

Great looking tool, but does it accept 7"+ blades? Looks like the standard blades have a different mounting contour than newer blades.

 

[DMucci]

Why not just get an electric foam saw?

<iframe width="560" height="315" src="https://www.youtube.com/embed/SiwJ1Z1nKuU" frameborder="0" allowfullscreen></iframe>

The US version is the 1575A

Those are good for straight through cuts but trying to contour with a right angle saw isn't comfortable.

 

[yamaha0343]

Since you're on the west coast, I'd talk to a couple of the fish docks and see which electric knives they're using.

 

[theoldwizard1]

Since you're on the west coast, I'd talk to a couple of the fish docks and see which electric knives they're using.

They don't use electric. Just a good quality knife that is sharpened often.

 

[theoldwizard1]

The Milwaukee M12 hackzall is pretty light, but has a limited number of blades available. I saw a video where a guy was using it as a replacement for a an air saw. He would take a bunch of new reciprocating saw blades and clamp them in a vice and grind the ends to the
matched the profile he need ! Much cheaper and a better selection.

 

[DMucci]

Bringing this topic back up because I still haven't found a good solution.

I've since bought one of these:

Cuisinart CEK-40 ($40)

I carved about 1.5 seats until the plastic gears inside stripped and the blades stopped moving.

So I bought this, Bosch PS60 ($99) with an 8" blade

and found out that a recip saw wont cut foam. It just grabs it and makes it vibrate. Turns out I need that shearing action of dual blades moving against eachother.

 

[dogdog]

maybe you needed these fabric cutters from the garment industry....... not sure if it cuts foams.... and expensive as hell to find out. somehow I got a package of their straight knives from ebay because it's HSS... lol.... I looked up the machine, it looks like it will cut foam straight no problem. but you do need a flat surface to work on. I remember seeing them in the garment factories. No personal experience with them.


http://www.allbrands.com/products/1...MIocDmxvnv2QIVl1cNCh3URQOJEAYYAyABEgJ90fD_BwE

 

[the gypsy]

Bringing this topic back up because I still haven't found a good solution.

I've since bought one of these:

Cuisinart CEK-40 ($40)

I carved about 1.5 seats until the plastic gears inside stripped and the blades stopped moving.

So I bought this, Bosch PS60 ($99) with an 8" blade

and found out that a recip saw wont cut foam. It just grabs it and makes it vibrate. Turns out I need that shearing action of dual blades moving against eachother.

Maybe you should take an old sawzall blade and modify it so that you have more of a knife blade rather than a sawzall blade. Notice the hooks on the blade, that is what I believe catches the material and shakes it back and forth. In other words grind down the teeth so that it resembles a knife.

 

[davethorik]

This reminds me, when this thread was first posted, about a day later was sent a video of a Hackzall carving a half pig.

 

[Kev442]

I went down the rabbit hole and the most powerful carving knife is 180 watts. The design is changed as the barrel of the knife becomes too big:

You could probably get a couple shipped to you for $40-50 each as they are $17. If they last a 1/2 dozen seats each, ordering 5 or 10 at a time at $30-35 delivered would just become part of the cost of doing business.

I also learned that the reason an "industrial" version does not exist is because they are not certified clean enough to be in industrial food settings.

 

[notlob]

Some electric filet knives to consider:

https://www.amazon.com/American-Angler-Electric-Fillet-Blades/dp/B00EJC4Z10/ref=as_li_ss_tl?ie=UTF8&qid=1481921115&sr=8-1-fkmr0&keywords=American+Angler+Pro+Electric+Fillet+Knife+Kit&linkCode=sl1&tag=smarthomeguide-20&linkId=79331fd1ff38515b32ba2dfc231841fb

https://www.amazon.com/Rapala-Heavy-Electric-Fillet-Knife/dp/B00F5EK3CG/ref=as_li_ss_tl?ie=UTF8&qid=1481918820&sr=8-1&keywords=Rapala+Heavy+Duty+Electric+Fillet+Knife&linkCode=sl1&tag=smarthomeguide-20&linkId=0c2ef8ee3809f811f5158786521930e6

https://www.amazon.com/Rapala-Lithium-Cordless-Fillet-Knife/dp/B005ZU1AJ0/ref=as_li_ss_tl?ie=UTF8&qid=1481921966&sr=8-6&keywords=cordless+electric+knife&linkCode=sl1&tag=smarthomeguide-20&linkId=cf470c78fe49cb94d6ed1a81749507a0

 

[6PTsocket]

Bringing this topic back up because I still haven't found a good solution.

I've since bought one of these:

Cuisinart CEK-40 ($40)

I carved about 1.5 seats until the plastic gears inside stripped and the blades stopped moving.

So I bought this, Bosch PS60 ($99) with an 8" blade

and found out that a recip saw wont cut foam. It just grabs it and makes it vibrate. Turns out I need that shearing action of dual blades moving against eachother.

I put a Bosch knife blade in my Bosch jig saw and it gave me the smoothest cut imaginable on foam. The true foam blades are the double blades that work like an electric carving knife but my results were glass smooth. I think the instructions recommended the #1 orbital position on the saw.

Sent from my SM-G900V using Tapatalk

 

[metaldad]

no one mentioned a porter cable tiger cub?
it's got balls, accepts standard recip blades, just no finesse.
don't know how to 'hot link' a pic to this forum, so, here's a cheap newer one on ebay
https://www.ebay.com/itm/RI2-Porter...848349?hash=item2ccffa4c9d:g:nycAAOSwesBalIuy

 

[kctyphoon]

Cordless commercial carving knife

https://www.centralrestaurant.com/W...tUSe6smwZcPvrFKY0N4le3TkVDd-u-choCcHAQAvD_BwE

Corded electric hot knife

https://www.google.com/shopping/pro...&ved=0ahUKEwj9lPr7__bZAhVmzlkKHRhHC4AQ8wIIiwE

Foam cutting supplies
https://hotwirefoamfactory.com/Industrial-Tools/

 

[jonesg]

Bringing this topic back up because I still haven't found a good solution.

I've since bought one of these:

Cuisinart CEK-40 ($40)

I carved about 1.5 seats until the plastic gears inside stripped and the blades stopped moving.

So I bought this, Bosch PS60 ($99) with an 8" blade

and found out that a recip saw wont cut foam. It just grabs it and makes it vibrate. Turns out I need that shearing action of dual blades moving against eachother.

Make your own gears from brass or buy gears .

https://www.khkgears.us/catalog/?c=...VEReFUcm1Kzy4z7_YVcQ-X8zvPRc8CwBoCUPsQAvD_BwE

 

[kctyphoon]

Check this thing out

What about a small band saw

 

[donpauli2]

Good body size but the air lines are usually a pain in the *** to maneuver with. I also need it to have a 6"-8" blade length.

That model uses a standard recip saw blade which you can get in a bazillion lengths and teeth combos. Well maybe just a mazillion


Sent from my iPhone using Tapatalk

 

[neitzel]

I realize it's not relevant to the original question, but maybe an oscillating tool would work? They seem to have a blade/attachment to get through about anything, and seem to be in your targeted size range.

 

[Sco Deac]

Kctyphoon nailed it. I just saw one at the local hobby shop and was going to post it and then saw KC’s video. They come in all sizes and price ranges. Here is one. https://www.creativesafetysupply.co...MI5pPC4p7-2QIVkYKzCh1DcgHnEAQYAyABEgL0GPD_BwE

 

[Lelandwelds]

A former employer used to burn an electric knife per employee per week in the upholstery dept. A new hire liked to fish at the coast. His favorite brand lasts about three months since adopted.

Try a new brand. Ask a salt water forum.

 

[Lelandwelds]

Kctyphoon nailed it. I just saw one at the local hobby shop and was going to post it and then saw KC’s video. They come in all sizes and price ranges. Here is one. https://www.creativesafetysupply.co...MI5pPC4p7-2QIVkYKzCh1DcgHnEAQYAyABEgL0GPD_BwE

For some reason, urethane foam isn't cut with hot wire. Big shops use bandsaw and die cutters. Custom seating for wheelchairs, motorcycles, and jet skis is cut with an electric knife.

Try another brand. Shop at Academy or Cabela'S or Bass pro Shops. Make a new fishing buddy. Changing work methods will not be fun.

You might make 10,000 at once and go with a foam injection system.

 

[Lelandwelds]

Bringing this topic back up because I still haven't found a good solution.

I've since bought one of these:

Cuisinart CEK-40 ($40)

I carved about 1.5 seats until the plastic gears inside stripped and the blades stopped moving.

So I bought this, Bosch PS60 ($99) with an 8" blade

and found out that a recip saw wont cut foam. It just grabs it and makes it vibrate. Turns out I need that shearing action of dual blades moving against eachother.

I called somebody who still works there. She walked over and called back. Try " Mister Twister". It is neon green and cheap to purchase.

 

[DMucci]

I went down the rabbit hole and the most powerful carving knife is 180 watts. The design is changed as the barrel of the knife becomes too big:

You could probably get a couple shipped to you for $40-50 each as they are $17. If they last a 1/2 dozen seats each, ordering 5 or 10 at a time at $30-35 delivered would just become part of the cost of doing business.

I also learned that the reason an "industrial" version does not exist is because they are not certified clean enough to be in industrial food settings.

Not a bad plan. I've found it's less about the size of the motor and more about the quality of the drive gears. Those are cheap enough to crack open and find out though.

That Waring commercial is tempting but an expensive way to find out if the internal gears are plastic or not.

For some reason, urethane foam isn't cut with hot wire. Big shops use bandsaw and die cutters. Custom seating for wheelchairs, motorcycles, and jet skis is cut with an electric knife.

Try another brand. Shop at Academy or Cabela'S or Bass pro Shops. Make a new fishing buddy. Changing work methods will not be fun.

You might make 10,000 at once and go with a foam injection system.

Correct, the hot knives are only good for that Styrofoam stuff. They'd probably burn or set fire to the high density rebond foam I'm using.

 

[Lelandwelds]

Former employer gets 10 times the typical life for these. They have three guys making custom wheelchair seating and headrests all day every day. They just buy them retail. Not sure which model.

https://www.walmart.com/ip/Mister-Twister-Electric-Fisherman-Filet-Knife/16563509