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Does anyone know how to make foam inserts for boxes?

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Forum topic by Jerry posted 01-28-2015 07:28 PM 1205 views 0 times favorited 17 replies Add to Favorites Watch
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Jerry

1767 posts in 1110 days


01-28-2015 07:28 PM

Topic tags/keywords: question

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:

Laser Cut Foam Inserts for Tool Boxes

Any and all help is appreciated.

-- There are good ships and there are wood ships, the ships that sail the sea, but the best ships are friendships and may they always be. http://geraldlhunsucker.com/


17 replies so far

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MrUnix

4211 posts in 1660 days


#1 posted 01-28-2015 07:32 PM

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.

Cheers,
Brad

-- Brad in FL - To be old and wise, you must first be young and stupid

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Loren

8301 posts in 3109 days


#2 posted 01-28-2015 07:35 PM

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.

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Jerry

1767 posts in 1110 days


#3 posted 01-28-2015 07:37 PM



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.

Cheers,
Brad

- MrUnix

That is a great idea! Thanks.

-- There are good ships and there are wood ships, the ships that sail the sea, but the best ships are friendships and may they always be. http://geraldlhunsucker.com/

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Jerry

1767 posts in 1110 days


#4 posted 01-28-2015 07:38 PM



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.

- Loren

Thanks Loren, this is also a wonderful idea. I had no clue about this.

-- There are good ships and there are wood ships, the ships that sail the sea, but the best ships are friendships and may they always be. http://geraldlhunsucker.com/

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MrUnix

4211 posts in 1660 days


#5 posted 01-28-2015 07:44 PM

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.

Cheers,
Brad

-- Brad in FL - To be old and wise, you must first be young and stupid

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Jerry

1767 posts in 1110 days


#6 posted 01-28-2015 11:16 PM



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.

Cheers,
Brad

- MrUnix

Hi Brad,

Yes, I was actually planning on that, I just needed to know how to start with the foam. Thanks.

-- There are good ships and there are wood ships, the ships that sail the sea, but the best ships are friendships and may they always be. http://geraldlhunsucker.com/

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gfadvm

14940 posts in 2151 days


#7 posted 01-29-2015 01:43 AM

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'll try to be nicer, if you'll try to be smarter" gfadvm

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Jerry

1767 posts in 1110 days


#8 posted 01-29-2015 02:08 AM



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.

- gfadvm

You guys are great, thanks gfadvm

-- There are good ships and there are wood ships, the ships that sail the sea, but the best ships are friendships and may they always be. http://geraldlhunsucker.com/

View mrg's profile

mrg

659 posts in 2461 days


#9 posted 01-29-2015 04:28 AM

What you are looking for is called pick and pluck foam

-- mrg

View longgone's profile

longgone

5688 posts in 2770 days


#10 posted 01-29-2015 04:37 AM

View Roger's profile

Roger

19867 posts in 2265 days


#11 posted 01-29-2015 01:07 PM

+1 to Greg. http://www.fastcap.com/estore/pc/Kaizen-Foam-p13435.htm. You cut it yourself, but, there’s a video on there or youtube that has good tips for custom cutting and melting, yep, I said melting.

-- Roger from KY. Work/Play/Travel Safe. Keep your dust collector fed. Kentuk55@yahoo.com

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Jerry

1767 posts in 1110 days


#12 posted 01-29-2015 04:05 PM

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.

-- There are good ships and there are wood ships, the ships that sail the sea, but the best ships are friendships and may they always be. http://geraldlhunsucker.com/

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Planeman40

805 posts in 2222 days


#13 posted 01-29-2015 04:19 PM

Ain’t this website a wonderful thing! Always gettin’ your questions answered. : )

-- Always remember: It is a mathematical certainty that half the people in this country are below average in intelligence!

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Roger

19867 posts in 2265 days


#14 posted 01-30-2015 12:18 AM

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.

-- Roger from KY. Work/Play/Travel Safe. Keep your dust collector fed. Kentuk55@yahoo.com

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Jerry

1767 posts in 1110 days


#15 posted 01-30-2015 12:39 AM



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.

- Roger

Well, thanks to your tip, I was able to source it at my local Woodcraft store.

-- There are good ships and there are wood ships, the ships that sail the sea, but the best ships are friendships and may they always be. http://geraldlhunsucker.com/

showing 1 through 15 of 17 replies

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