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mfingar
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Posted: 8/14/2006 10:30:54 PM
[Last Edit: 3/7/2008 1:34:47 PM by mfingar]






Many folks ask me how I cut my case foam.

I follow the "6 P's"

Prior
Preparation
Prevents
Piss
Poor
Performance

In other words; the hard work comes before cutting.



Razors and electric carving knives are crude...I've used hot wires to cut foam for years. Unfortunately, a handheld hot wire cutter is difficult to keep straight, and 90 degrees to the surface. So I designed the unit shown here. Works Great!


Essentially, it's a 24" x 24" piece of particle board, supported on some 2" x 2" lumber, with a hole drilled in the center to run some florists wire through, connected to a support arm. I modified a Wonder Cutter to handle my electronics.

The cutter can be easily made for under $50....Google "Hot Wire Foam Cutter", and you'll get many instructions on how to build one yourself.

____________________________________________________________________________

EDIT 3/7/08

I recently replaced my battery stack with a household light-dimmer switch and a 25 volt, 2 amp transformer I got from RadioShack. I also got some Ni-Chrome wire instead of the steel florists wire...works great!!









_____________________________________________________________________________



So here's the Prep:

First:
Trace the item you want in the foam with a Sharpie onto posterboard, or card stock.

Err on the "inside" to make a tighter fit.

Next:
Clean-up your lines. Use a straight-edge to make everything parallel.


Then:
Cut out your shape, and tack it to the foam. This will allow you to visualize placement of multiple objects. If you're adding multiples...Plan, plan plan. Layout everything before you cut. Make sure it's what you want. You can get creative with your layout at this point.


Then:
Plunge a "pilot hole" with a box cutter.


Next:
Feed the wire through the pilot hole.


Then:
Turn on the cutter and slowly work your way all the way, around the template, like a jigsaw. Ending at the pilot hole.


Next:
Remove the template and the plug. Keep the template for future projects.


Then:
Cross-cut the plug to match the item's height. Re-insert the remaining plug into the hole.


Finally:
Assemble, and case the hardware.



Good luck, and enjoy.

Just take your time...It'll work out great.

Mark
LaRue Tactical Supporter, Former Air Assault Guy.
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Posted: 8/14/2006 10:35:54 PM
Thats great!

Thanks for the writeup!
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iNuhBaDNayburhood
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Posted: 8/14/2006 10:42:44 PM
NICE!!! I totally FUBAR'd my last attempt at such a foam layout...
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Posted: 8/14/2006 10:48:07 PM
A man of your intelligence deserves such a fine collection af hardware.

Nicely done!
danpass
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Posted: 8/14/2006 10:51:13 PM
very nice, just move the foam around like using a band saw


side question: where do you get your foam?
Psalm 54:7 For He has delivered me from all my troubles, and my eyes have looked in triumph on my foes. yep
bear3351
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Posted: 8/14/2006 10:53:01 PM
That looks great!!! THANK YOU for the tips.
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ICEAGE
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Posted: 8/14/2006 10:53:36 PM
Very nice man, two questions.
1, Why do you have a scope on the sbr upper?
2, How do you carry a handgun with a suppressor?

mfingar
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Posted: 8/14/2006 10:58:09 PM

Originally Posted By ICEAGE:
Very nice man, two questions.
1, Why do you have a scope on the sbr upper?
2, How do you carry a handgun with a suppressor?




1, It's a QD Tijicon Accupoint...works great on a 10.5" barrel. (1.5-4X)

2, I have a thigh-rig, with a suppressor pouch. Mounting it in the case saves lots of space.
LaRue Tactical Supporter, Former Air Assault Guy.
mfingar
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Posted: 8/14/2006 10:59:28 PM

Originally Posted By danpass:
very nice, just move the foam around like using a band saw


side question: where do you get your foam?



These guys are great!!!!!!
LaRue Tactical Supporter, Former Air Assault Guy.
mjpjr45
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Posted: 8/14/2006 11:04:12 PM
Really nice write up. Only problem is this is 2 months too late for me. I totally screwed up the one I did for my laptop and printer. Oh well it works for now, I know what to do when I decided to redo it.
danpass
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Posted: 8/14/2006 11:20:46 PM

Originally Posted By mfingar:

Originally Posted By danpass:
very nice, just move the foam around like using a band saw


side question: where do you get your foam?



These guys are great!!!!!!


Lol, I have them bookmarked already


I thought maybe there might be another game in town
Psalm 54:7 For He has delivered me from all my troubles, and my eyes have looked in triumph on my foes. yep
eye_spy
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Posted: 8/15/2006 12:10:24 AM
GREAT, INFORMATIVE POST! Thanks.
sparky923
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Posted: 8/15/2006 1:31:14 AM
My new hero.
Thank you very much.
600nitroexpress
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Posted: 8/15/2006 1:48:07 AM
wow



awesome thx
mfingar
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Posted: 8/15/2006 6:45:02 AM
[Last Edit: 8/15/2006 6:46:42 AM by mfingar]


I had rounded the sharp edges with a small butane torch on this project...gave it a softer look & feel. A sheet of foam keeps the items separate.
LaRue Tactical Supporter, Former Air Assault Guy.
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Posted: 8/15/2006 6:57:03 AM
VERY nice write up! Thank you sir!
usagold
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Posted: 8/15/2006 7:08:56 AM
very nice job well done
lt557
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Posted: 8/15/2006 8:55:18 AM
Great write up. Thank you.
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M4A2_L073754
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Posted: 8/15/2006 9:21:49 AM
First your pics and now this. What else do you have...???

Excellent post.

MN
QUIB
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Posted: 8/15/2006 10:14:38 AM

Originally Posted By mfingar:
Many folks ask me how I cut my case foam.

Mark



I don’t give a shit how you CUT your foam…………………………I wanna know how you afford all those toys to put IN your foam!

Just kidding Mark, very nice write-up and VERY sweet toy box!


AERO SCOUTS........Un-armed and un-afraid!

Thanks Aimless!
danpass
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Posted: 8/15/2006 10:25:53 AM

Originally Posted By mfingar:
Many folks ask me how I cut my case foam.

Mark



You should tell them you have your servant, Chuck Norris, stare at it until the foam pieces cut themselves out.


Psalm 54:7 For He has delivered me from all my troubles, and my eyes have looked in triumph on my foes. yep
DrMark
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Posted: 8/15/2006 11:13:03 AM

Very nice, Mark.



mfingar
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Posted: 8/15/2006 11:47:06 AM

Originally Posted By QUIB:
I wanna know how you afford all those toys to put IN your foam!


You'd be surprised what someone would pay for a 40 year-old kidney.
LaRue Tactical Supporter, Former Air Assault Guy.
heffelfinger007
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Posted: 8/15/2006 11:56:49 AM
Super walk thru, I am glad you did this, as I am about to start my rifle case in a couple weeks.
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B-O-A-T-S
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Posted: 8/15/2006 12:34:15 PM
Good job on the write up!!!!

I vote for a Tack. Mods... what do you think?
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danpass
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Posted: 8/15/2006 1:03:01 PM

Originally Posted By B-O-A-T-S:
Good job on the write up!!!!

I vote for a Tack. Mods... what do you think?


+1
Psalm 54:7 For He has delivered me from all my troubles, and my eyes have looked in triumph on my foes. yep
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