Form Fitting

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Forum topic by dpwalker posted 01-08-2012 08:19 PM 1080 views 0 times favorited 2 replies Add to Favorites Watch
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273 posts in 3069 days

01-08-2012 08:19 PM

I am wondering what LJ’s are using to form fit an object into a box. IE: tools, pistols, knives. forks etc. I would like a tight fitting foam type material that is still soft & flexible like foam. I thought about high density foam but am unsure how to get a perfect fit.

-- You have not really lived until you do something for someone who can never repay you.

2 replies so far

View JAAune's profile


1854 posts in 2554 days

#1 posted 01-26-2012 09:32 AM

I cheat a little and use multiple layers to fit objects into boxes. Foam is something I’ve not done yet but it probably will work as well with my method as it does with plywood.

Put a thin layer of material down into the box. In my project it was a piece of thin cardboard wrapped in cloth. Next, trace out the object on a piece of stock of the right thickness. For plywood a scroll saw is perfect to cut out the pockets. I cut my openings over-sized so I could line everything in cloth. When this is placed on the first layer it’s hard to tell that the pockets weren’t carved or routed out.

Perhaps the foam could be cut on a scrollsaw as well? I don’t know the answer to that. It wouldn’t hurt to make templates from plywood or mdf though before cutting into the foam.

-- See my work at and

View Moron's profile


5032 posts in 4131 days

#2 posted 01-26-2012 10:09 AM

1/multiple layers of styrofoam cut to suit and laminated together

2/expandable spray foam (minimal expansion )………remove what isnt needed…..perfect fit followed by “flocking”

cutting foam, like the stuff for mattresses to fit a gun/pistol/knife………..nightmare

on choice #2………cover the object with saran wrap and if possible, cover the object with a release agent before wrapping with saran wrap

-- "Good artists borrow, great artists steal”…..Picasso

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