If you have ever considered doing lost foam casting

[jkopel]

Check out this hot wire CNC machine!

http://www.youtube.com/watch?feature=player_embedded&v=y_xR-iueN2U

[Dr Stan]

Its very easy to do and especially good for a one-off application. I've also used it to make aluminum patterns by doubling the shrink allowance on the foam model. I also made the surface quite smooth by applying a coat of wood glue thinned 1:1 with water.

One word of caution. Make sure you do this where you have lots of ventilation, or better yet outside. The fumes from the foam are especially nasty and bad for ones health.

[Oldbrock]

Tried it once in the school shop. Had to evacuate the whole school. We were popular with the students but not so with the adminstration. Pete