How to cut hollies in foam pads...

[vkurup]

Am helping out HID take some work samples ... She is looking to take it in some sort of foam padded box as taking them on the train is going to be an interesting challenge.

Found a foam padded suitcase at Maplin, the ones that are used for transporting cameras
http://www.maplin.co.uk/flight-case-with-foam-36796

Looks good, but I need some advice on how to cut hollows into the foam such that the stuff can be put into these. Any ideas? I have never cut foam but had a quick trawl on the Interweb.

Any alternative suggestions on how to carry such things e.g. Delicate Electronic goods

 

[Rooter]

Like this?

 

[Rooter]

I just found the "instructions" my belgian colleague wrote for me, bare in mind, mine is a Peli case with foam that is built in 1cm blocks, so its very easy to manipulate. Its also quite a big case and houses a rack mount PDU, but generally should help... Let me know if you need more pics...


The inside consists of 4 layers of foam (from top to bottom):

Top "studded" layer which fits in the top hinged part of the case
To stop this part from covering the devices when opening the case (it tends to fall down) this was secured using double sided adhesive tape

A thick layer of foam divided in 1 cm2 parts
The necessary spaces for each device were removed (remove the foams as whole blocks, not as individual bits!) and then sliced length wise using an exacto knife (different height for each device) and put back in place. This lifts the devices slightly above the top of this foam layer and keeps them pressed down by layer 1 when the case is closed (see the image from Nicolas). Note that i kept at least 2 rows of foam as divider to keep sufficient rigidity of the foam.
The PDU has an additional notch on the right so you can use 2 fingers to remove it more easily.
When the PDU is removed a hole is visible through the bottom of the foam (i tried to keep it in the middle as much as possible to ease removal) and plastic layer (see next step) to remove the entire layer as a whole.
After verifying the correct height and layout for all devices use a stiff black plastic sheet and more double sided adhesive tape to secure it to the bottom of the "assembled" foam. This will prevent any devices from falling out when removing the foam and keep all the height spacers neatly in place.

Another thick layer of divided foam
Just like layer 2, but without the plastic material spaces were created for all accessories

Bottom layer
No changes needed

 

[vkurup]

Like this?

View attachment 8076

Yup..

Reading thru the instructions.. Not sure how I will be able to cut it out.. I m going to use a sharp utility knife, but can easily cut the sides, but still struggling to see how I can cut the bottom bit.

On my way to Maplin tosee how the box looks like in real life. Will ask the sales guys, but it is highly unlikely that the young gelled boy will know anything - luckily there is a Harper next door with a bunch of 'old men' who know what they are talking about...

 

[Rooter]

Cut all the way through the shape. Then subtract the height of the item and cut that off. Then replace the "bottom" of the shape into the hole. You will have to line the bottom of the layer if it's going to be removed.... This is easier to show rather than type!!! Lol

 

[Vice]

electric carving knife

[video=youtube;mXhT7WtIsTg]http://www.youtube.com/watch?v=mXhT7WtIsTg[/video]

 

[Lump]

if its anything like the pelicase stuff, its pick and pluck foam....

 

[vkurup]

if its anything like the pelicase stuff, its pick and pluck foam....

Indeed, picked the case from Maplin... And it is indeed pick and pluck foam... So no need to carve anything!!!!

Rooter.. If you are looking to upgrade ur bag then let me know.. This box will be on fleabay once HID is done with her exams in Nov...

 

[Rooter]

Indeed, picked the case from Maplin... And it is indeed pick and pluck foam... So no need to carve anything!!!!

Rooter.. If you are looking to upgrade ur bag then let me know.. This box will be on fleabay once HID is done with her exams in Nov...

depending on the depth of the items you are putting in, pick and pluck may not be best, hence why i said to take out the shape in a complete block if possible, cut to the correct depth and replace. otherwise it will rattle around in there making the point of a foam lined case pointless!

Upgrade my premium Peli case that was £300 for a maplin one? no ta.. i have been informed i can drive over mine in a car, use as a floatation device if i ever get stranded at sea! *

*not tested either yet.

 

[SwingsitlikeHogan]

Melt it!!

Actually a rotary screwdriver with a circular 'saw' attachment - like the thing your dental hygenist uses to polish your teeth - except it has a sharp cutting saw-like edge. Use a very small diameter one to get you into right into the corners.

[no idea if this will work but pretty much how I'd approach it if I was working with wood when making a mortice for a mortice and tenon joint]