How to make kerf cuts in polystrene or styrofoam boards?

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Topic by Dalec posted 02-01-2009 02:10 AM 6081 views 0 times favorited 14 replies Add to Favorites Watch
View Dalec's profile


40 posts in 3903 days

02-01-2009 02:10 AM

Have been looking at ways to insulate my garage door. I found several web sites that sell material to insulate residential garage doors. Some are foil-bubble pack-foil, others are foil-polyform-foil, still others are polystrene sheets with kerfs cut into the sheets to allow the polystyrene to bend and slid into place. Rather than buying these kits, I am thinking about buying polystrene sheets from a big box store and cutting to size and cutting kerfs to allow me to bend the sheets to slip into the openings on the inside of the garage door.

My question is what would you use to cut the kerfs that would make clean cuts without melting the foam or making a mess? Does anyone have experience cutting grooves into polystrene sheet goods?


View MRTRIM's profile


744 posts in 3903 days

02-01-2009 02:24 AM

a handsaw might work well

View Dalec's profile


40 posts in 3903 days

02-01-2009 03:48 AM

As I looked at the images of the kits, the kerf cuts look to be about 1/8” to 1/4” in width. So a handsaw would likely be too thin. This is only my guess.


View Kindlingmaker's profile


17 posts in 3722 days

02-03-2009 04:52 PM

A kerf cut does not have to be flat on the inside bottom to work. Cut in thin pie shapes with an Olfa knife (I use the large ones) or something like that. You can make a simple jig for a cutting guide that will give the same depth and width on each cut.

-- What do you mean I can't use a coat hanger for 12 ga wire?

View Dalec's profile


40 posts in 3903 days

02-03-2009 05:17 PM

Thanks Kindlingmaker


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09-13-2018 12:00 PM

Curve cutting usually is difficult and have to be precise. I use a lot of curve cut here in Park Colonial. It will take up a lot of time. Where I came from in Margaret Ville, the culture normally use curve cut. Back to Uptown@Farrer, everything is pretty straightforward. The recent project, Riverfront Residences, had me take up so much time in this. I do not suggest curve if you want to finish up project fast. Be quick to deliver and must be quality finishing. All the best – 8 Hullet

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