Cutting foam question: How to cut clean lines?

[Funky]

So you have a case, you want to put guns and gadgets in it. You want the pieces secure and you also want them to display well when opened.
(btw, this is the thread that's inspiring this: http://www.therpf.com/showthread.php?t=79433 )

First, what type of foam is best and where can it be aquired? Next, is an xacto really the best way to cut foam so that you don't get jagged,rough edges? I'm just thinking you trace the pattern then carefully cut around it, but then how do you dig it out? Or do you simply cut all the way through and have a solid piece under THAT one?
Ahhhhhhh!!! Any tips will certainly help! :cry

 

[shanclaw]

Maybe try hot wire cutting. Its mainly used for cutting through styrofoam. It might work for impact foam. Or it could melt and mutilate the foam in a smelly horrible mess.

So you have a case, you want to put guns and gadgets in it. You want the pieces secure and you also want them to display well when opened.
(btw, this is the thread that's inspiring this: http://www.therpf.com/showthread.php?t=79433 )

First, what type of foam is best and where can it be aquired? Next, is an xacto really the best way to cut foam so that you don't get jagged,rough edges? I'm just thinking you trace the pattern then carefully cut around it, but then how do you dig it out? Or do you simply cut all the way through and have a solid piece under THAT one?
Ahhhhhhh!!! Any tips will certainly help! :cry

 

[Sulla]

I used a sharp x-acto knife and two layers of foam in my Trek O'Brien's tool case: http://www.therpf.com/showthread.php?t=58007&highlight=O'Brien

 

[CustomCreations]

hey-
Right, you need the high density case foam, best thing to do is head to the nearest foam supplier- sorry i cant be more helpful there but it should be standard issue to any good dealer.
Measure the depth of the case-
measure the depth of the item you want to protect/or how deep it should sit -
then deduct the two.
You now have two measurements- you need your foam cut to these thicknesses.
Ie
depth of case- 6 inches
depth of item- 2 inches
so you need one sheet of foam at 4 inches,
and one at 2 inches.
You cut your shape needed in the 2 inch foam, you can use an extended craft knife blade
then just join the two foam sheets up- you get a perfect 'bottom' this way
You can use a jigsaw to cut the foam, even a sharp serrated bread knife can do it, just try to make as few strokes as poss, without squeezing the foam....
You can buy precut foam- its harder to find but it can be bought with hundreds of tiny squares almost cut out from it. You then just pull the squares you dont need right out...

D

 

[Funky]

Measure the depth of the case-
measure the depth of the item you want to protect/or how deep it should sit -
then deduct the two.
You now have two measurements- you need your foam cut to these thicknesses.
Ie
depth of case- 6 inches
depth of item- 2 inches
so you need one sheet of foam at 4 inches,
and one at 2 inches.
You cut your shape needed in the 2 inch foam, you can use an extended craft knife blade
then just join the two foam sheets up- you get a perfect 'bottom' this way

That's kins of what I was thinking.
Thanks, guys.

 

[modeleers]

For foam travel-cases (sometimes called a 'trap case' by musicians) - I use a simple Electric Carving-Knife. (introduced in the 60s, with 2 side by side blades that work forward & backward - canceling the stick & pull of a single blade). These are always to be found at Thrift stores for - between $1 & $15 dollars. The length of blades varies (IMO- the longer the better)

 

[joeranger]

This is much harder than it seems. You really do need a hot wire to make it perfect. The eye will be drawn to imperfections like a magnet.
You also need a good template to work from.

 

[modeleers]

To be sure I was correct in my recommendation - I just checked with a representative at Anvil (which specialize in fabricating custom travel cases) & the types of foam in gun, camera & musical cases is knife cut (with a type of "band saw") - a 'hot wire' will Not cut (without melting) the types of foam - discussed herein.

 

[duck]

Electric carving knife. And don't force the blade, just take your time. You'll be amazed. And to cut a shape out of the center of a piece, use the same concept you would cutting wood: pop a hole wide enough for the blade in the center of the shape away from any edge, insert blade and cut towards the closest edge and follow that.

 

[Bowelrock]

I would not use a hot knife.. I have made cases for high end airsoft pistols, and a really sharp knife a good template, and some patience is the best thing. You can achieve really nice results with that method.. Hot knives melt and discolor the foam, creating a gross surface that can actually mar/scratch the surface of what your going to be storing.

Just my $.2 cents after having tried a hot knife..

 

[Mostly Fantasy]

I've found a razor saw to give a nice clean cut....