Easiest way to cut chunk out of canoe saddle???

[Ryan Viser]

I'm installing a sealed lead acid battery for my pumps. I'm cutting a chunk out of the front of the saddle just big enough for the battery to fit in but I'm having trouble figuring out how to rip that chunk of foam out, there's no way for me to get behind it to cut it free. Any ideas?? And please spare me the jokes about "Yeah, hee hee, get a kayak and don't worry about that crap!" :roll:

[DonShreve]

I'd try using a keyhole saw to cut the opening, then snake a little rope saw behind to cut the back edge loose.
Hope this helps.
Don

[Adam Willard]

I showed you already!!! Dont you remember???? Forstner bit, mark you depth with tape on the shaft. The depth is the length or width of the battery. That depends which way you install it.
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[rickyrod]

cut it in a grid pattern the same depth as the stop cuts around the edge the more the better, than pull each piece out . should break off at the base. remember too small and theyl break off in the middle.as long as they are free from the exterior peice or the piece next to it it will pop out easaly.

[T Yamashita]

i'd do the drill bit on the sides, then cut the sides to the needed depth with a keyhole saw, then cut some lateral lines 1cm apart and cut them out. I would make it 1cm shallower than i needed and scrape it out with dragon skin to the final depth. just my 2cents! ty

ps. you missed a great 'tot run on sat! I hope adam is better... :roll:

[painterbob]

hook up jumper cables to a battery and a thin copper wire, form it to the profile of the battery.. but once you connect the last end of the copper wire , and complete that circuit it gets red hot fast and with a steady hand make your move!

[Sasquatch]

I used a small serrated steak knife. Cut the dimensions needed for the void to the dept of the knife. My blade was about 4 inches long. Then there is a long process of digging out the center. I used a whole saw and made several drills and dumps to get the majority of mini cell out. Then picked and pulled with pliers and knife.
I mounted my batteries in a Pelican case with a switch on the outside. Ran a 1/2" conduit from front of saddle to rear, the glued on a 1/2 LB 90 then sealed wires in conduit and ran the exposed wires down to the pump. Maybe more information than you wanted.

[Dave Thomas]

Hot wire! Take a coat hanger or piece of baling wire or some other piece of stiff steel wire, bend it into a square-cornered U shape, heat it up with the Barbeque grill or a torch or something, and use it to cut. You'll probably have to reheat a couple of times, but it works nice and clean.

[Ryan Viser]

Ding Ding Ding, we have a winner! Thanks Dave Thomas! Painter Bob your idea was an extremely close second, however, Dave's similar method without the risk of blowing myself across the garage won out, even though I managed to brand my arm twice in the process. It's ok though, I'd take a brand to the face over running out east w. no pump system :) Thanks for the all the help guys!

[Dave Thomas]

Glad I could help!

[Roger]

A small controlled-explosion with C-4.