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Cutting Gun Case Foam (lots of photos)
mfingar  [Team Member]






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
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-RotorDemon-  [Team Member]
Thats great!

Thanks for the writeup!
iNuhBaDNayburhood  [Team Member]
NICE!!! I totally FUBAR'd my last attempt at such a foam layout...
OFFSHORE  [Team Member]
A man of your intelligence deserves such a fine collection af hardware.

Nicely done!
danpass  [Team Member]
very nice, just move the foam around like using a band saw


side question: where do you get your foam?
bear3351  [Team Member]
That looks great!!! THANK YOU for the tips.
ICEAGE  [Member]
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  [Team Member]

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.
mfingar  [Team Member]

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!!!!!!
mjpjr45  [Team Member]
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  [Team Member]

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
eye_spy  [Team Member]
GREAT, INFORMATIVE POST! Thanks.
sparky923  [Member]
My new hero.
Thank you very much.
600nitroexpress  [Member]
wow



awesome thx
mfingar  [Team Member]


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.
jdmpimp  [Team Member]
VERY nice write up! Thank you sir!
usagold  [Member]
very nice job well done
lt557  [Team Member]
Great write up. Thank you.
M4A2_L073754  [Team Member]
First your pics and now this. What else do you have...???

Excellent post.

MN
QUIB  [Team Member]

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!


danpass  [Team Member]

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.


DrMark  [Team Member]

Very nice, Mark.



mfingar  [Team Member]

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.
heffelfinger007  [Team Member]
Super walk thru, I am glad you did this, as I am about to start my rifle case in a couple weeks.
B-O-A-T-S  [Team Member]
Good job on the write up!!!!

I vote for a Tack. Mods... what do you think?
danpass  [Team Member]

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
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