Planing large pieces

[georgy]

Hello,

I've got an interesting problem and I thought you guys might be able to provide some insight.

I have several huge 4' x 8' x 1'6" blocks of tooling foam, 450 lbs each. The blocks are pretty rough-cut, and what I need to get out of them is square blocks.

My thought right now is to cut the blocks down into 6" x 8' x 1'6" sections and plane the sides of those flat using a planar like the one in this video:
http://www.youtube.com/watch?v=t51SSP12Gk8

What do you recommend?

[Magicman]

Welcome to the Forestry Forum, georgy.    

I have never been involved with planning large pieces, but I think that member metalspinner has.  If he hasn't, he always wanted to.   ;D

[mikeb1079]

if you cut em down to 6" x 8' can't you run em thru a normal planer?

also welcome to the forum!!

[hackberry jake]

1'6" is 18". I have a woodmaster that'll plane 18"x6". I would be afraid that the feed rollers would squish the foam though.

[red oaks lumber]

find a planer that planes atleast 18" wide and that can open up to atleast 6" high.that should be a easy fix to your problem.
you might have to chainsaw the origanal piece in half to get the hieght to fit on a bandmill to precut your sizes.
if you lived close to me, that looks like a 3 hr job.

[fuzzybear]

There was a post here a little while ago, with a video of a man that made a sled table used with a router and straight bit. He was using it to plane 2'+wide slabs for furniture. Maybe some one else can remember where it was.  It was a simple design made out of plywood I believe.  Well that was easy... it was mentioned on another thread complete with this link. 
https://forestryforum.com/board/index.php/topic,59260.msg868272.html#msg868272
FB

[Tools]

I've done that sort of thing before.

First, if you can find a regular planer (ones that large aren't very rare, or expensive for that matter), that would work best.

If you go with the sled/router route, just keep in mind that you can't make wood to wood tolerances too tight.  The one in the top video is a GREAT design, BUT, it will allow the router to ride upwards, not making a full depth cut leaving you with an uneven surface.  Therefore, you generally need to feed REALLY SLOW (you'll want to speed up as you go, seeing how well it's working!), keep an eye on the bit.  Once it shows signs of dulling, replace it (they're resharpenable, fairly cheap), and use a carbide bit in a GOOD router, advertised as 3hp, with a 1/2" collet and 1/2" shank bit.  I'd use a straight bit, probably a 1/2" straight bit.  Easily obtainable are bits that'll flatten 1 1/2" or so per pass with radius edges which seem like they'll work GREAT.  The problem is that these are the bits that will likely "ride up".  They're good if you're holding the router and maintaining good down pressure.  But on a rig like that, any additional down pressure WILL flex the carriage and cause all sorts of problems. 

That's all I can think of right now. 

Tools

[redbeard]

If these are the type of foam used for dock floatation I believe they cut them using a hot wire. Just thinking!