Cut Cubed Foam neatly

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  • Cut Cubed Foam neatly

    My drill case recently broke, so I ordered one of these flight cases from ebay. How do you cut out this foam neatly? The videos on Youtube show two layer foam boxes. You cut out the top piece, and then stick it to the solid base. The base of mine comes with a single thick piece of cubed foam.
    Aluminium Flight Case (460x330x150mm) with Foam block and egg foam lid. Cubed foam block in base - easy cut foam. Egg foam insert for case lid. Quick Catch Mechanism with Padlock Loops. Case Size Comparison.pdf. | eBay!

  • #2
    Originally posted by JK0 View Post
    How do you cut out this foam neatly?
    Have you tried an electric knife? But, I don't know how neat it would actually be.

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    • #3
      http://www.ebay.co.uk/bhp/foam-cutter

      (e.g.... )

      Google woz my friend....
      I am legally unqualified: If you need to rely on advice check it with a suitable authority - eg a solicitor specialising in landlord/tenant law...

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      • #4
        Originally posted by theartfullodger View Post
        http://www.ebay.co.uk/bhp/foam-cutter

        (e.g.... )

        Google woz my friend....
        Thanks, but I don't think that's going to be able to cut an impression of a drill in a solid piece of foam, is it?

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        • #5
          As said above a hot wire cutter is the best, but its probably not worth buying one with wide enough jaws if its only a one off task.

          Very sharp craft knife, mark the shape you want, dig down inside the line in stages till you break through and then use sandpaper to finish off.

          Better than a craft knife is a wood chisel, it's longer and stiffer (oo-er missus), but you will need a couple of different widths, 1"(25mm) to cut the straight lengths and 1/8"(3mm) to get round small corners. (That's where the sandpaper comes in to smooth things off).

          Good investment, you can use them later for general woodwork, fitting door hinges, etc.

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          • #6
            Thanks Nukecad, but I think once again you don't understand my problem:

            Originally posted by JK0 View Post
            The videos on Youtube show two layer foam boxes. You cut out the top piece, and then stick it to the solid base. The base of mine comes with a single thick piece of cubed foam.
            I don't see how I can express this any clearer.

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            • #7
              Originally posted by JK0 View Post
              I don't see how I can express this any clearer.

              Originally posted by JK0 View Post
              I don't think that's going to be able to cut an impression of a drill in a solid piece of foam,
              But you didn't state this in your first post. We needed details.

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              • #8
                If it's cubed (not a solid piece of foam) it should be easy to cut each cube with scissors.

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                • #9
                  Originally posted by Mrs Mug View Post




                  But you didn't state this in your first post. We needed details.
                  Nothing quoted that has not been there all along.

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                  • #10
                    I'm not sure just what you are trying to do then?

                    As I understand what you are saying-
                    You have a rectangular slab of foam, one piece. (Rather than two layers).
                    You want to cut this out to take the shape of a tool, in your case a drill.

                    So take the foam out of the case, lay the tool on the foam and mark around it.
                    Use a hot wire cutter, a sharp knife, or even a copingng saw to cut the shape out of the foam.
                    http://www.screwfix.com/p/forge-stee...Fa4h0wod-yQC5g
                    The best tool to use will depend on how dense/stiff the foam is.
                    (You can cut in from one edge, it won't matter once you put it back in the case).

                    To cushion under the tool then there are two choices,
                    • Once you have removed the shape cut a slice from the shape you have removed and press it down to the bottom of the hole. With most foam it will stay there by friction, but you could use a little glue on one edge. (or some sticky tape underneath where it won't show once in the case.
                      Or:
                    • Before starting slice your block into two layers and only cut the shape in one of these (like the videos you have seen?).



                    I've done it in the past to fit cameras, lenses, etc. in this type of case.
                    (I used to use the 'cut it out then take a slice from the cut-out' method, it gives better results),

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                    • #11
                      Thanks NC. I think you understand me now. Just I imagine it will look like an abortion when the drill isn't in its case. How well did yours turn out?

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                      • #12
                        It always worked out just fine, as long as you make a neat job of the cutting then the slice that you push down the hole will fit well and you will hardly notice it is a seperate piece.

                        Even if it is not a very neat job then its down the hole, so it's covered by the equipment, or not seen because the case is closed.

                        I have even once or twice cut out the shape of the equipment and then just pushed a rectangular block of foam down there.

                        PS. when cutting the slice cut it thicker than you think you need, you can always trim a bit more off later which is neater than adding another slice if you cut it too thin.

                        There is a third option that leaves the foam in one piece:
                        You can use a sharp knife to cut down to a set depth and then 'pluck' (dig out) the material to be removed.
                        Of course this usually leaves an uneven bottom, but again most of the time this will not be seen.

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                        • #13
                          Okay, well I tried that. It is impossible to cut a slice off the cut piece, as the cubes start to separate. It does look like an abortion. It's going in the bin.

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                          • #14
                            Oops. It sounds as if the foam you had was pre-cut into semi attached cubes? Sorry I hadn't clocked that, I've always used 'solid' slabs. OK, so you can bung a rectangular block down the hole. If you want a neater finish though then the next job is to buy a piece a new piece of foam and start again. Craft or diy shops sell foam in various sizes, you should be able to buy online. Just checking the web - with the precut cube stuff you are supposed to use the 'dig out' method. I've never come across it myself.

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                            • #15
                              Heres a 'How to' for if you find yourself with this cubed stuff.
                              http://www.pelicancasescanada.com/ho...-foam-inserts/

                              Personally I don't like the look of that stuff and would get a solid piece, or sheets to build up in layers.
                              Don't know how big or deep your case is but maybe something like this would let you build up the right thickness-
                              https://www.ebay.co.uk/p/X-5-Camera-...d=162122797647

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