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Making The Mighty Goliath Hotwire Machine!

by Creativeman on January 12, 2009

Table of Contents
Making The Mighty Goliath Hotwire Machine! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Intro: Making The Mighty Goliath Hotwire Machine! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Step 1: Additional instruments made with same technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Step 2: Pieces of project needed to constuct instrument. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Step 3:

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Step 4: One example of a dimmer control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Step 5: Closer look at arm assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Step 6: Apparatus for testing various components and Wiring Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Step 7: Details for mounting dimmer switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Step 8: Bottom Mounting Piece details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Step 9: Top arm details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Step 10: Cutting stencil for painting on name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Step 11: Making Design Decisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Step 12: Completed instruments, ready to go to work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

http://www.instructables.com/id/Making-The-Mighty-Goliath-Hotwire-Machine/

Author:Creativeman
Retired, doing art work now. Great. Have the time and the money to spend doing what I want to do.

Intro: Making The Mighty Goliath Hotwire Machine!

Complete instructions for the making of the Mighty Goliath Hotwire Machine. Materials and directions are shown in each step, image notes. See my other instructables
for sample work, signs, etc. Creativeman.

Image Notes
1. One completed instrument, colors may vary primarily for visual interest.

Image Notes
1. Cut letters from hotwire

Step 1: Additional instruments made with same technique

I have made several instruments like this, namely to use in a class I plan to hold. I think it is a viable art form and is relatively unknown to the general and artistic
community. People find it hard to believe you can get such detail in the lettering. Try it, I think you will like it. Disclaimer: IF YOU DON'T UNDERSTAND THE
ELECTRICAL WIRING, DO NOT ATTEMPT! GET QUALIFIED ELECTRICIAN TO HELP. I have used one of these machines for 15 years with no problems, not even a
broken wire. So if things don't seem to be working right, you have probably done something wrong. A few additional tips: Try to keep temperature as low as possible. You
want to melt the foam, not burn it. Use only with adequate ventilation. Some people may be sensitive to the vapors produced. Use care around the wire! It is hot and will
burn you. Don't let young children play with it. It is not a toy.

Image Notes
1. On this one, the transformer and dimmer control are mounted underneath the table.
2. Natural colors used. Note transformer placement.
3. Not completed yet. Will be like the red and yellow model.

http://www.instructables.com/id/Making-The-Mighty-Goliath-Hotwire-Machine/

Step 2: Pieces of project needed to constuct instrument.

Most pieces of the instrument assembled together for this instructable. The transformer, dimmer control and wires will be added in the next view. View image notes for a
complete explanation of the various parts.

Image Notes
1. Red blank, i.e., the table for the machine. White dot is indicator for drilling
attachment screw
2. White dots are where holes will be drilled. Top hole is for foot attachment while
bottom two are for transformer mount.
3. White pieces of wood, with brown markings for drilling holes in these pieces.
Pieces are cut to shape with bandsaw.
4. Various hardware pieces needed to assemble the machine.
5. Feet, pieces of 3/4 inch dowel, 1.5 inch long,with brown indicators for predrilling.
6. Arm support
7. Arm
8. Bottom wire mount
9. Bottom mount adjusting screw
10. Lower wire attachment screw
11. Upper wire attachment screw

Image Notes
1. One completed instrument, colors may vary primarily for visual interest.

Step 3:
Electrical components needed for the machine. All items are listed in the image notes.
Costs: Electrical cord: $1.25; Transformer: $6.90; Dimmer switch: $4.99 (push on/off type); Nichrome wire: I bought 100 feet for $2.50! Wood parts probably add a dollor
or so to costs, same with various mounting screws/hardware. So for between $10 and $20 dollars you can have your own hotwire machine. I have seen these on the web
for much more money. This machine will accomplish the same thing. I have made larger machines to be able to cut larger pieces of styrofoam, or EPS foam. I just
changed the length of wire, the transformer and the sizes of the wood components, obviously.

Image Notes
1. Surplus electrical cord, 6ft long.
2. Dimmer switch, push on/off type.
3. Transformer, this one is a 6vac, 1A model.
4. Hook up wire, 22awg. Lengths in picture approximate. Don't cut until ready to
install/connect to power.

Image Notes
1. Transformer: 6.3V, 1Amp.

http://www.instructables.com/id/Making-The-Mighty-Goliath-Hotwire-Machine/

Image Notes
1. Dimmer switch.

Step 4: One example of a dimmer control

In this picture, an inline lamp dimming switch is shown. It seems to work ok, although has not been tested over time. This type of control is quite a bit more expensive
than dimmer switches used in other models.

Image Notes
1. Dimmer control used on this instrument.

Step 5: Closer look at arm assembly

This is a close up of one arm made for the blue machine. All are similar. These two pieces are made of common pine lumber, 3/4 inch thick. The arm it self is about 8
inches long by 3/4 by 1/4in. Pieces are glued and screwed for strenght.

http://www.instructables.com/id/Making-The-Mighty-Goliath-Hotwire-Machine/

Image Notes
1. Arm made of wood had enough spring to keep wire taught when heated.
2. Holes drilled for visual purposes, only. Length of this piece is about 4 and 1/2in. Width is 2in.

Step 6: Apparatus for testing various components and Wiring Details

This is a helpful item to test transformers, switches, wiring, etc. before final assembly.

Image Notes
1. There is a wire here! Used to test components before final assembly.

Image Notes
1. Spring is used to keep wire taught. As current is supplied, wire will go slack due
to expansion. On the insrument, there is enough "spring" in the top arm to act as
this spring does.

http://www.instructables.com/id/Making-The-Mighty-Goliath-Hotwire-Machine/

Image Notes
1. Hotwire here
2. Secondary side of transformer
3. Primary side of transformer
4. Transformer. Solder all connections here. (4).
5. Dimmer switch.

Step 7: Details for mounting dimmer switch.

Shown in the pictures are the milling or routing of a depression for mounting the dimmer. Placement of dimmer and knob are shown.

Image Notes
1. How dimmer looks installed. Top view.

Image Notes
1. I counter sunk this screw head to keep table top clear.
2. Top view.

http://www.instructables.com/id/Making-The-Mighty-Goliath-Hotwire-Machine/

Image Notes
1. A routed depression on under side of table to mount dimmer switch.

Image Notes
1. Dimmer successfully mounted.

Step 8: Bottom Mounting Piece details

In this shot, details of the bottom wire mounting piece are shown. A 1/8 inch hole is drilled in the end of the wood piece to accept a 8-32x1in. machine screw. To this
screw, the power wire from the transformer and the hotwire itself will be attached. In the center of the bottom mount, a 1/2 inch hole is drilled with a forstner bit. A 1x6in.
wood screw with washer is used to attach the piece to the table. By moving the mounting piece slightly in any direction, hotwire can be adjusted to be plumb in two
directions and give right angles when slicing through the foam.

Image Notes
1. Note bottom mounting piece with machine screw in end (with nut) and wood screw and washer holding piece to table.
2. This arrangement allows for adjusting positon of wire when installing cutting wire at end of process.

Step 9: Top arm details

Here, the top arm has been drilled to accept the machine screw as shown. The hole is 1/8 in, and the machine screw is an 8-32x1in.

http://www.instructables.com/id/Making-The-Mighty-Goliath-Hotwire-Machine/

Image Notes
1. Screw to top arm detail. The screw had been flattened on two sides with a belt
sander. A 1/16in.hole is then drilled as shown. This is where the hotwire is
attached in the final step.

Image Notes
1. Another arm and screw assembly.

Image Notes
1. Screws used.

Step 10: Cutting stencil for painting on name

A stencil is made by selecting the fonts used on the word processor, printing the words out in duplicate, and then cutting the stencil with a craft knife, or scalpel.

http://www.instructables.com/id/Making-The-Mighty-Goliath-Hotwire-Machine/

Image Notes
1. Stencils used to label machine.

Image Notes
1. Paper templates, i.e., letters printed on computer word processor then cut out to
attach to foam blank. These are the letters cut out for stencil.
2. Letters that have been cut out of foam blank, not painted, but shown to give an
example of the quality obtainable.

Step 11: Making Design Decisions

Shown are various instruments being tested for color combinations, placement of components, lettering choices, and so on. See image notes for more details.

Image Notes
1. Prototype modeling.

Image Notes
1. Placement of drilled holes

Image Notes
1. More sampling, working out decorative details, letter placement, etc.

Image Notes
1. Letters cut from foam to test placement on table. So far so good.

http://www.instructables.com/id/Making-The-Mighty-Goliath-Hotwire-Machine/

Image Notes
1. I like these!

Image Notes
1. Letters being stenciled on. This is step one, the shadow.

Step 12: Completed instruments, ready to go to work

Many hours of creativity lie in store for the craftsperson who has one of these. Enjoy!

http://www.instructables.com/id/Making-The-Mighty-Goliath-Hotwire-Machine/

Image Notes
1. On this one, the transformer and dimmer control are mounted underneath the table.
2. Natural colors used. Note transformer placement.
3. Not completed yet. Will be like the red and yellow model.

http://www.instructables.com/id/Making-The-Mighty-Goliath-Hotwire-Machine/