How to Cut Styrofoam Billets
Styrofoam billets are made of the same material as other Styrofoam products but they are sold in larger and thicker blocks. These billets have a variety of uses in building and crafts, but they are most often used to construct docks, boats and other structures that must float in water. They are light weight and resistant to water, making them a good choice for many projects. Cutting Styrofoam billets is a fairly straightforward process performed with basic hand tools. Does this Spark an idea?
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Instructions
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Measure the area where you are installing the Styrofoam billet to determine the proper length and width that is must be cut to.
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Lay the billet on a flat work table. A paved area is best for larger billet blocks, but you can lay it on the ground if no paved area is accessible.
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Transfer the length and width onto the Styrofoam billet, using the tape measure and a black marker.
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Put on a dust mask and safety glasses and pick up a hand-held rips saw. Place the serrated saw blade at one end of the black marker line and saw through the line using an even motion until reaching the other side. If the billet is thicker than approximately 1 foot, saw only half way into it instead of trying to cut all the way through. Turn the Styrofoam billet over and finish cutting through it from the other side.
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Put down the ripsaw and pick up a curved keyhole saw. Use the keyhole saw to cut any lines on the billet that are not straight. If there are no curved lines, you can skip this step.
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Pick up a rasp, which is a metal bar that has holes similar to a grater. Move the rasp back and forth over the cut edges of the Styrofoam billet to smooth them down and create a more professional appearance.
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Tips & Warnings
The rasp can also be used to shorten the billet if you realize that some areas are only slightly larger than needed.
