I just finished a box that I want to turn into a harmonica case for a friend of mine. He's a professional musician and has several harmonicas, all of varying sizes. I want to make a foam insert for the inside of the box that is cut to fit each harmonica exactly. I don't have a laser cutter and it would probably be too expensive to have it cut commercially, but I'm looking to do something of the same quality seen here:
Way back in my youth, our boy scout troup had a booth where we would cut styrofoam shapes to sell in order to raise money for our camping trips and such.. we used a hot wire cutter and it did a beautiful job of it. I've seen them in hobby/craft stores for around $50 or less and might be something to look into.
FastCap sells some layered foam where it's all stuck together
and you cut out a shape with a exacto knife, peel up that
layer and then you can cut deeper if needed.
There's this dark grey very firm foam they ship computers
and TVs and stuff like that using it for the ends. It can
be cut with knives and hand saws, resawn on the band saw
and so forth. It can be reglued using rubber cement.
So if you can find enough of it you can plan things out,
cut it apart, make your internal cutouts, then glue it
back together.
Way back in my youth, our boy scout troup had a booth where we would cut styrofoam shapes to sell in order to raise money for our camping trips and such.. we used a hot wire cutter and it did a beautiful job of it. I ve seen them in hobby/craft stores for around $50 or less and might be something to look into.
FastCap sells some layered foam where it s all stuck together
and you cut out a shape with a exacto knife, peel up that
layer and then you can cut deeper if needed.
There s this dark grey very firm foam they ship computers
and TVs and stuff like that using it for the ends. It can
be cut with knives and hand saws, resawn on the band saw
and so forth. It can be reglued using rubber cement.
So if you can find enough of it you can plan things out,
cut it apart, make your internal cutouts, then glue it
back together.
You might also want to consider lining whatever you use with some velvet.. you can hack the foam with whatever method you want without too much concern for final look. Just as long as the shape is right. It would also give IMHO a much more classy look than the utilitarian one of just foam.
You might also want to consider lining whatever you use with some velvet.. you can hack the foam with whatever method you want without too much concern for final look. Just as long as the shape is right. It would also give IMHO a much more classy look than the utilitarian one of just foam.
I'm pretty sure that foam Loren is referring to is Ensolite (closed cell high density foam). It is great stuff to work with. Contact Shanks Veterinary Surgery Tables and they may let you have a bunch of small pieces for the shipping.
I m pretty sure that foam Loren is referring to is Ensolite (closed cell high density foam). It is great stuff to work with. Contact Shanks Veterinary Surgery Tables and they may let you have a bunch of small pieces for the shipping.
Fantastic guys. Thank you so very much for all your information and help. I just determined there is a dealer 10 minutes from my house. Roger and Greg, thank you so much for the link, it got me to exactly where I need to be.
I actually have 2, 2×4 sheets of that Kaizen foam that I will eventually get round to doing something with. Been thinking of some under-bench drawers with the necessities close at hand.
I actually have 2, 2×4 sheets of that Kaizen foam that I will eventually get round to doing something with. Been thinking of some under-bench drawers with the necessities close at hand.
Hi Blackie,
You're right I had forgotten that I used an electric knife to do reupholstering my FJA 40 Land Cruiser. Thanks.
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