Foam core V groove cutter - Express yourself - Demonstration or Protest sign Maker - Foamcore, foam board

thingiverse

This is a 120 degree V-groove cutter for foamcore board (foam board, foam core). Design is included in Fusion 360, for you to remix with the tolerance you require. Using this 120 degree V-groove cutting tool, you can make triangular shapes out of foamcore. As a triangle is the strongest shape, it is useful for making strong tubes such as for a handle for a sign. To enable one to better express one's self, and to prevent arm strain in the process, it's useful to hold your message up high with a stick. In some cities, such as NYC, demonstrators are prohibited from using wooden sticks to hold up signs. Using this cutter, you can make relatively strong (and safe) triangular tubes using foamcore to serve as a suitable sign holder. Starting with a 20x30 inch sheet of foamcore, you can make a handle and still have enough real estate to share your message. <h1>V-Groove Cutter</h1> <h2>Bill of Materials:</h2> 3D printed items: - blade base - handle M3 hardware: - 20 mm bolt (1 quantity) - 30 mm bolt (2 quantity) - M3 nuts (3 quantity) Utility blades (2 quantity) Super glue for retaining the nuts <h2>Instructions</h2> 1. Install the three M3 nuts in to the handle. Secure with superglue and let cure. 2. Bolt handle to the base using 20mm M3 bolt. 3. Install first utility blade from underneath the base. CAUTION: Blades are super sharp. Use one finger and gravity to hold the blade in place while gently snugging the 30mm bolt to hold the blade in place. 4. Repeat step 3 with the second utility blade. <h1>Express Yourself! How to make a Foamcore Sign</h1> <h2>Bill of materials:</h2> - Foamcore board, 20x30 inch recommended - Zip ties - 8 inch (2 quantity) - Packing tape (2 pieces for handle) <h2>Tools:</h2> - 120 degree V-groove cutter (see above) - Straight edge - Utility knife or blade - Ruler - Marker - Side cutters (to clip excess ends of zip ties) - Optional: Drill and drill bit <h2>Fabricate the handle:</h2> Note: - For portrait orientation of your final sign, cut along the short edge - For landscape orientation of your final sign, cut along the long edge Mark out the following dimensions along one edge of your foam core. Make marks at the following distances from one edge: 2 inch (Groove) 3-1/2 inch (Groove) 5 inch (Groove) 5-1/4 inch (Cut) See photo above for clarification. You will end up with lines 2" from edge, then 1-1/2", 1-1/2" and finally 1/4". IMPORTANT: These lines indicate where to hold your straight edge. This V-groove cutter is designed to cut exactly 1-inch away from the straight edge. So, the grooves will be cut 1-inch away from the lines you drew. Cut three grooves, with the straight edge on the three lines marked "Groove". While curring, press down on the handle so that the V-groove cutter base remains on the foamcore. Then, peel from one end to remove the cut portion out from the groove. Sometimes using a small screwdriver will help start the peeling and enable smooth one-piece peeling of the cut V-ribbon. Finally, using the utility knife, cut directly on the last line indicated as "Cut". You will now have a four-sided section with three V-grooves. Wrap the handle into a three-sided tube, with one of the edges overlapping. Wrap with two pieces of packing tape to keep the handle tightly closed. Use one piece at the end, and one piece about mid-way. The other end will be secured when installed onto the sign. <h2>Attach the handle to the sign:</h2> Now, take the large remaining piece of foamboard and mark where you want to install the handle. I prefer that the handle reach about half-way across the sign, thus leaving a good amount of handle extending past the sign. Mark four holes for the zip ties, two holes near the bottom of the large piece, and two holes near the top end of the handle. You can optionally use a drill to puncture the foamcore, but a screwdriver or awl will work fine. Make holes large enough to accommodate the zip tie. Thread the two zip ties through the holes as shown in the figure. Place the triangular handle with the slit in the handle toward the back of the sign. Tighten the two zip ties and clip off the excess zip tie with sidecutters. Add your message to your sign, and then get out there and express yourself!