A hot wire cutter is used to slice the foam in a Pelican case but what to cut for perfect circles in the middle? For tins of course. Ideas? Pictures of your custom foam inlays?
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Cut Foam in Cases
- Thread starter DuncanHynes
- Start date
Heat a pellet tin in a campfire and before you roast the sausages carefully push the tin edge first into the foam?
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You can just take an old pellet tin and sharpen the edge and cut a circle by spinning the tin but you will have to make it pretty sharp. I do this to make plugs for my air cannon.
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A nice trick to cutting foam is a scrollsaw, not the jig- saber saw but a floor model. Using a #5 spiral you can get some exact cuts. Scrollsaw clubs are pretty common, a google search will reveal clubs in your area. I had a problem with a case and the side turret. It left a noticeable dimple in the foam. I took the 27mm socket for the Cricket gauge removal, made a couple of turns and plucked out the circle. Another trick is use a holesaw and drill it in reverse as not to tear the foam.
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You can use plywood to sandwich the foam between 2 pieces clamped together and cut the rifle shape and pellet tins through both pieces of the plywood. I would use my CNC router table but I know that is not an option for most folks.
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Gundog that's the best idea I have heard yet! That's something most can do with just a jig saw of band saw. I made a hot wire cutter for foam many years ago out of wood. Looked kind of like a scroll saw and used D cell batteries to heat the wire. Worked good as I recall.
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Hi guys. Good info. In the very near future I will be attempting to cut out the foam in my rifle case. I have a roto-zip. I think it might cut the foam pretty good, but I'll have to make a test run first.Question: Are you using the existing foam that comes with the case? and if so how are you cutting the depth? Or do you order 2 piece foam for the top and 2 piece foam for the bottom, make your cuts, then glue them together?
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You cut top layer all the way in the shape of the object, there is usually another layer under that left alone. My hot wire cutter is great but must go slow and have good light or even a headlamp. I used a caulk pencil.
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My plano case came with just 2 piece foam. 1 for top and 1 for bottom. I'm on amazon trying to find a foam pad, maybe 1inch thick to put on the bottom under the existing foam that I will cut out.
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If you don't mind spending a little bit you can buy foam on eBay that has the precut squares that you just pinch out they are cut in about half inch grid lines. Sweet water media is the name of the company on eBay I believe? They sell music recording equipment. It worked really nice!
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