Hello everyone, I'm looking for some advice on the best way to cut the foam in my SIP panels to accept OSB surface splines. I'm trying to decide what tool is best suited to make the 1.5" deep 7/16" wide pocket in the EPS. Unfortunately, the use of hot tools to burn the foam is not an option in this case. Do you have any suggestions on what mechanical means work the best? Thanks!

there are bits made for routers that can make the cut.

there is a way to do it with a small circular saw, but both ways make a big mess, need to have something to catch the debris

What can you you use hot iron? that are used sideways simple quick.

See what others here suggest.

Most companies will pre-cut them to your specs at no cost.

Two inexpensive options include the wire brush wheel and a router.

A four inch diameter wire wheel can be attached to threaded rod with washers and nuts to create a very cheap wire wheel used in a drill. All the parts cost less than ten bucks at the hardware store.

or

take a 1/2" drill bit and place it in a router that has a 1/2" collet. To get the correct depth of cut, simply place the bit in a vise and snap it off to the correct length. Grind to clean dull point and you're ready to cut grooves. When using a router, you need to cut in the correct direction to prevent the bit from wandering. The best router to use is one that has adjustable speed. Also, you should always shoot for a spline groove wider than the spline itself. Let the mastic due the sealing and allow the splines to slide easily in the groove. If you make it too tight, pulling panels together is more difficult.

Lastly, have a foam rasp on hand to dull the corners of the foam and this will help ensure the panel joints slip together better.

Al