How to neatly open up a EPO foam airframe

[Dave Wave]

I am doing a turbine conversion on a foam airplane and need to cut out a large additional hatch. What is the best way to neatly cut the foam. I have tried saws but they all to seem to rip rather than cut .

Are there any tricks to cutting the angle so the plug fits back in and hopefully adds some integrity. In my case the plug will have to be removable, but can be screwed in place.

Any links/tips appreciated!

[Evan D]

I use a metal straight edge and scalpel. If we need to cut deeper I have a very sharp long exacto blade.

[kallend]

Same as Evan, and if there is one I try to cut along an existing panel line,

[Dave Wave]

The area i need to remove is quite thick, so I think i will need to use a thin kerf saw. Any recomendations for a good epo saw blade?

[Tigercat]

What about using a hot wire or a hot knife?

[Evan D]

I wouldn’t with this kind of foam…

[RRHandy]

This is what I use to open up foam planes, there is a wider blade also, always use a sharp blade.

https://www.amazon.com/sharpness-OLFA-Stainless-Auto-Lock-description/dp/B00M6NXHLS/ref=sr_1_1?c=ts&keywords=Shop+Knives&qid=1660128529&refinements=p_4%3AOlfa&s=power-hand-tools&sr=1-1&ts_id=553222

[Gilatrout]

Micromark sells a razor blade with micro serrations that has worked well for me.