Ive seen a lot of hotwire cutting rig videos and this by far is the most complicated set up by far! If this was the first video I watched on hotwire foam core cutting I would have been turned of the idea of trying it myself.
What if you extend the shorter profile both ways with a straight line, till both the templates are the same length ? Then both ends of the wire would travel the same distance so you wouldn't need this differential setup
Is this Southbay like San Jose California? There are so many bays in the United States, but from the background of some of the videos it looks like southern San Francisco Bay
I appreciate the video and this man taking his time to share his setup and experience, but the peanut gallery comments of "did you tie this off", "did you do that", "why dont you do it that way", "I usually do it such and such a way", was very off putting. Let the man share his knowledge without trying to sow off what you know at the same time as some kind of superiority complex. The look on his face sometimes said it all to me exactly how I felt watching this.
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