Working On 'Kingspan'?

Stigura

I need to rout, channel, otherwise remove some 'Kingspan' type board. I have some here. It's sandwiched between sheets of thin steel. I want to dig out the material along one edge. I need to put a length of wood in there. With me? Here's a photo, look. Thousand words 'n all that.

Trying to figure out how to make a half tidy job of it.

Basically, I need to take out about an inches depth of the foam material. As ye'd know, it doesn't exactly respond like wood. Trying to figure out how best to do it. What tool, even.

Five foot length, by the way. So, 'Painstakingly slowly and carefully, with a thin, sharp blade' isn't really what I'm hoping to hear. I could be at it for days, that way! 😬

Thanks.

dathi

a router with a straight cutter dust will fly every where though

jack of all

Multi tool with a cranked blade, slow but won't through as much dust around as the router option?

mikehn

Get something like one of those old fashioned wire coat hangers, the thicker the wire the better. Bend the wire to fit between the metal on both sides and out at the sides to the depth you require, using a blowtorch or similar heat the wire til red hot and it will slice thought the foam like the proverbial hot knife through butter. I have used this on one occasion myself and had zero issues.

FrancieBrady

Actually did something similar to make a cheap and effective door for a space.

This hopefully makes sense. Not absolutely perfect but some spray foam would help if voids are critical.

listermint

Track saw with depth set. Run about 5 passes up the length of it. Then crack it out with hand or hammer.

Sleepy

Heated wire is the way to go here.

listermint

https://www.boards.ie/discussion/comment/121634362#Comment_121634362

It is but its mighty expensive for such a small job. Did my entire house EWI. That. Was fun. The heated wire was nothing short of a pain in the hole. More time fixing it than anything else.

FrancieBrady

https://www.boards.ie/discussion/comment/121634266#Comment_121634266

Scary if you aren't confident with a saw. 😁

Stigura

https://www.boards.ie/discussion/comment/121634219#Comment_121634219

And, @FrancieBrady wins todays cigar!!! 👍️ Believe it or not, Francie, a Door is exactly what I'm working on too! 😁 Couldn't make this up,could ye? The length of timber's for the hinges to attach to 🙂

And, in the interim, I've been out there, doing what I probably should have done yesterday! 🙄 Chisel seems to work well enough, lads.

Router, Multi Tool, Track Saw? Yep. I'm pretty sure They'd be the business. Unfortunately, I have none of them to hand. Hot wire? Believe it or not; I actually Do own a purpose made, electric powered 'Hot Wire' tool! Got it for working on polystyrene. Hot knife through butter is right!

Unfortunately, with the pantheon of materials we largely refer to, collectively, as 'Kingspan'? I can only guess this particular lot is the wrong type. It goes through poly like a knife. My 'Kingspan'? Well, paint dries too, doesn't it? 😬

Anyway, yeah. That's me sorted. Thanks :) I guess I should have had at it with everything to hand, first. But, past experience ..... Like I say; Different sort of material than I worked on before. Happily, in this case! ;)

listermint

https://www.boards.ie/discussion/comment/121634610#Comment_121634610

100 percent agree. Slowly slowly catchy monkey