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Forum topic by LoyalAppleGeek posted 08-05-2016 02:06 AM 397 views 0 times favorited 10 replies Add to Favorites Watch
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LoyalAppleGeek

120 posts in 361 days


08-05-2016 02:06 AM

Topic tags/keywords: foam case gun headphone computer box kaizen foam custom

Greetings and salutations fellow Lumberjocks!

I build custom cases for guns, headphones, computers, etc. While Kaizen Foam is great for this application, the price is ridiculously high for a sheet of rubberized air pockets. I’m looking to find a foam that would work well for custom cases at a low price. It doesn’t have to be specifically intended for that purpose, any nice looking foam will be perfectly useable.

I look forward to hearing your response!

Thank you everyone.


10 replies so far

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clin

514 posts in 462 days


#1 posted 08-05-2016 02:39 AM

Amazon has Kaizen foam for $25 for a 2’ x 4’ sheet. Doesn’t seem ridiculous to me. Foam is expensive. And something like this that has removable layers is going to be more expensive.

Check with local foam suppliers in your city or nearest large city. See what they have. As with anything, you’ll get a better deal if you buy more.

I think you’ll also get the best price locally. Shipping foam purchased online is expensive because it takes up a lot of room. While the foam is not necessarily manufactured locally, when it is shipped in bulk it is compressed in very large blocks. The local supplier is the one that cuts it into thickness.

Just an aside, local supplier was telling me about the large compressed blocks of foam getting shipping in. He said one time the banding, that holds the block compressed, failed and the block more or less exploded and blew out the trailer. They have a huge machine, like a GIANT vise (something like 8’ x’ 8’ jaws that open 20’) that they release the foam blocks in. Pretty interesting to see how something as simple as foam gets handled.

-- Clin

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LoyalAppleGeek

120 posts in 361 days


#2 posted 08-05-2016 04:17 AM

And very interesting to see the power a block of foam can have! We’re pretty rural here, but I’ll check into suppliers around here. Also, memory foam would work quite well. If it’s from a fancy place like Sleep City, it’ll probably cost more, but more generic types might be decently priced.

Thanksfor the information! I’ll keep checking the sources I get.

View MadMark's profile

MadMark

978 posts in 919 days


#3 posted 08-05-2016 04:57 AM

Styrofoam, flocking, & felt are cheaper. Shape the Styrofoam with a hot soldering iron & ventilation & mask. Once the fit is right, flock the cavity. Then put sticky felt on the flat top, cutting out the flocked cavity.

M

-- Madmark - Madmark2150@yahoo.com Wiretreefarm.com

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LoyalAppleGeek

120 posts in 361 days


#4 posted 08-06-2016 01:58 AM


Styrofoam, flocking, & felt are cheaper. Shape the Styrofoam with a hot soldering iron & ventilation & mask. Once the fit is right, flock the cavity. Then put sticky felt on the flat top, cutting out the flocked cavity.

M

- MadMark

MadMark, I think you may have just saved my life. I’m not sure what you mean by “Put sticky felt on the flat top, cutting out the flocked cavity”. Do you just mean sticking felt to the bottom of the lid?

Thanks!

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LoyalAppleGeek

120 posts in 361 days


#5 posted 08-06-2016 03:16 AM

Although, there is one problem. I need something with give to it. I build these cases to be universal, so I can’t mold them to exactly the shape I need. That’s why I was thinking memory foam, but that is also difficult to find a good price on. I’m looking at upholstery foam now.

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MadMark

978 posts in 919 days


#6 posted 08-06-2016 03:47 AM

Assume the Styrofoam is 2’ thick. You draw the object outline & melt away the cavity with a soldering iron, test fitting as you go. The completed cavity is flocked, but the top of the styro is still flat. You put flat sticky felt on the Styrofoam surface and then cut out the shape of the flocked cavity. When the item is inserted into the flocked cavity for display, only the felt will show. With the item removed, the felt & flocking will match for a clean professional look.

For a medal box just leave the Styrofoam uncut and give a piece of green and blue felt. Medal pins will push thru & hold & the cust can use either felt (green/Army, blue/Navy).

I’ve sold them by the dozen at the local Army/Navy shop.

M

-- Madmark - Madmark2150@yahoo.com Wiretreefarm.com

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LoyalAppleGeek

120 posts in 361 days


#7 posted 08-06-2016 03:54 AM

Got It! Thanks for the quick reply and clarification, that was super easy to understand. The only issue I can see is that, styrofoam likes to fall apart. It seems like with repeated removal if the item in the case, it would begin to chunk apart. Have you ever had an issue with this?

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MadMark

978 posts in 919 days


#8 posted 08-06-2016 06:02 AM

The flocking stabilizes the cavity surface, but yes, with time it will show wear. I use the stiff adhesive backed felt and that doesn’t show much of anything. Glue the Styrofoam into the box before final assembly.

Rockler, MLCS, Grizzly etc. All have flocking supplies & felt.

M

-- Madmark - Madmark2150@yahoo.com Wiretreefarm.com

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LoyalAppleGeek

120 posts in 361 days


#9 posted 08-11-2016 09:16 PM


The flocking stabilizes the cavity surface, but yes, with time it will show wear. I use the stiff adhesive backed felt and that doesn t show much of anything. Glue the Styrofoam into the box before final assembly.

Rockler, MLCS, Grizzly etc. All have flocking supplies & felt.

M

- MadMark


I just did a couple tests on the styrofoam from the packaging of one of my tools, and found that the layer of melted polystyrene created by the forming process adds significant structural integrity to the cavity. Combined with the thin foam I overlay it with, it may work. Where do you recommend getting styrofoam blocks? I can only find insulation (expensive) and floral foam (not the same as standard styrofoam).

Thanks for that tip, if I can get some good styrofoam I think I can have som fun with this and get good results.

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MadMark

978 posts in 919 days


#10 posted 08-11-2016 11:12 PM

You can buy 2” Styrofoam at your local home store – search for rigid foam …

M

-- Madmark - Madmark2150@yahoo.com Wiretreefarm.com

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