Need Custom Foam Suggestions
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Need Custom Foam Suggestions


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Old 05-20-2013, 12:49 AM   #1
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Default Need Custom Foam Suggestions

I need to find some good shock absorbing foam I can customize for several cases I will be putting together... for everything from audio and camera gear to a handgun, clips and ammo to a telescope and accessories. I have never done any projects like this so any suggestions would be appreciated. I suppose I will need several layers of one or two inches to get the depth I will need for the telescope and just maybe glue and stack them as it would be much easier than trying to cut for a depth of about ten inches. I have not looked at foam manufactures or dealers because I figure I will get better starting points from feedback here. I do want the fit to be snug... especially for the handgun so the foam that has per perforated "pop out" areas doesn't sound too appealing to me. I am guessing after traces the items on paper using an x acto knife would be the way to go. Suggestions? Thanks!


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Old 05-20-2013, 01:12 AM   #2
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Foamfactory.com. They even have the pick and pluck stuff.


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Old 05-20-2013, 02:57 PM   #3
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Xacto isnt the best way. It will work but it will not look very professional. Hot wire is what you will need. You can google it. You can even make them fairly easily with a few pieces you can get here and there. Most folks dont do layers, or at least I never have, Get the depth you need, cut out the piece and then cut the plug to the depth you want to keep.
Sme folks like using an electric carving knife and freezing the foam. I have never tried it that way, but I have seen some results and they looked very good.
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Old 05-20-2013, 11:34 PM   #4
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Get a hot knife from the craft store for straight cuts. And an adjustable hole saw for circles.
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Old 05-21-2013, 02:50 PM   #5
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A serrated blade steak knife works quite well for smooth cuts in foam. Some folks even use the electric versions.
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Old 05-26-2013, 05:44 PM   #6
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I have used my electric fish fileting knife.
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Old 05-26-2013, 10:00 PM   #7
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Still researching... I am thinking cutting for the telescope optical tube which is about 17" long by about 9-10" in diameter is where it will be tricky, to get a long and deep, curved cut out of a block of foam may be tricky...

I also will need to research some quality, but not too expensive cases... they will all need to be shock absorbent themselves with lockable features... I would prefer not to have to use pad locks, especially for the handgun... that case in particular must be a good lockable case... I may also check out finger print locking for that but I'm pretty sure that will be too pricey. Will probably have to go with some type of standard spinning numerical locks as seen on briefcases.


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