How to Cut Insulating Foam

Insulating foam can be purchased at most large hardware stores and home centers. Depending on the brand, the foam may be pink or blue. The cutting technique you use will depend on the foam's thickness. No matter how you cut it, always make certain that you are wearing eye protection and a breathing mask, as dust and tiny particles will get everywhere.

Difficulty: Easy

Instructions

Things You'll Need:

• Soft-lead pencil
• Utility knife
• Straight edge
• Band saw
• 100-grit sandpaper
• Breathing mask
• Eye protection

1. Mark where you wish to cut your foam. Use a soft-lead pencil to mark directly on the foam. Use a light touch and allow the indentation made by the point of the pencil to mark your cutting line.

2. Lay your loam on a firm, flat surface.

3. If you're cutting foam of 1 inch or less in thickness, lay a straight edge along the cut line and score a line at least 1/4-inch deep using your utility knife.

4. Lay the foam on the straight edge of a table with the scored line at the edge of the table. Snap the foam overhang down sharply, snapping the foam cleanly along the scored cut.

5. If you're cutting foam thicker than 1 inch, use a band saw. Feed the foam through the band saw at a fairly fast rate while keeping the cut line parallel with the blade to avoid any chipping or rough edges.

6. Sand the cut edge lightly with 100-grit sandpaper just enough to smooth it. Wear a breathing mask and eye protection whenever sanding.

Tips & Warnings

• Always wear a breathing mask and eye protection when cutting insulating foam. Dust and small particles will get into everything. Keep insulating foam away from open flames.
• Do not cut your foam with a hot knife, hot wire cutter or other hot instrument. If you ignore this advice, make certain you work in a well-ventilated area and do not inhale the fumes.