I don’t know of anyone who has built one for 1" foam but it has been mentioned a time or two off-hand. I should think it pretty straight-forward as the entire cutter is a pretty simple build anyway. All my cutters so far have been used for cutting sheet foam of 1/4" or less and, with my printed flywheels and bearing offset of 6mm, the stroke is just shy of 1/2" (12mm).
You would need to offset the flywheel bearing by a bit more than 1/2" to get a full 1" cut. Balancing the flywheel might be a bit trickier but should still be doable. The needle flex would be greater so it would probably be best to increase the distance (height) between the flywheel and the needle guides to keep the flex and friction manageable. This increased distance would also require a longer needle, of course, and possibly an increase in the needle’s diameter for stiffness. With just the changes to the flywheel/offset and the cutter height, I think everything else should work fine,
After a couple of years of inactivity there’s a renewed discussion going on over in the RCGroups forum, focusing on KISS aspects of the needle cutter right now. Several rather crude but very effective cutters have been built and demo-ed – one in just the past couple of days – that demonstrate just how simply a cutter can be fashioned.
Take a look, starting about here, for the most current discussion…
Please keep us up to date on your progress… and feel free to join in the discussion(s) going on in the FliteTest and RCGroups forums.