How to cut foam that is not pick n pluck

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wahoowad

wahoowad

Member
Nov 4, 2016
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Virginia, United States
This old Plano 'Gun Guard' rifle case is about 25 years old and just uses convoluted style foam to sandwich firmly against the rifle. I want to use it for my Uragan but closing the case is really tight. I don't think I want that pressure so tight up against my barrel shroud and moderator.



The case itself isn't very thick so I do not think I can use aftermarket pick n pluck foam to replace it. There wouldn't be enough space for another bottom layer of foam to go underneath the pick n pluck. And I can't just cut the outline of the Uragan out because there needs to be a foam layer underneath the cutout to keep it from bottom out against the case side.

Instead I think all I need to do is scallop out the outline but not cut all the way through the foam. How can I somewhat evenly scallop out a certain depth? I think cutting a 1" deep outline will work. Suggestions?
 
What you're asking will be a challenge. Though I may have a solution for you. I use this to cut and craft styrofoam. I'm sure it'll work for foam as well, just make sure you're in a well ventilated area. Not sure how much these kits cost in comparison to new gun case.

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Good luck
 
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This old Plano 'Gun Guard' rifle case is about 25 years old and just uses convoluted style foam to sandwich firmly against the rifle. I want to use it for my Uragan but closing the case is really tight. I don't think I want that pressure so tight up against my barrel shroud and moderator.



The case itself isn't very thick so I do not think I can use aftermarket pick n pluck foam to replace it. There wouldn't be enough space for another bottom layer of foam to go underneath the pick n pluck. And I can't just cut the outline of the Uragan out because there needs to be a foam layer underneath the cutout to keep it from bottom out against the case side.

Instead I think all I need to do is scallop out the outline but not cut all the way through the foam. How can I somewhat evenly scallop out a certain depth? I think cutting a 1" deep outline will work. Suggestions?
Click to expand...

Cut the tips off the foam and problem solved
 
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That is not difficult. Use an exacto knife blade screwed into a soldering iron.

It will cut through foam just like a hot wire will.

Outline what you want to cut, then cut. Trim down the cut out pieces to act as a pad underneath your gun.

I have been doing that for years and it works just fine, but be careful, that blade is HOT.

Don't ask me how I know this......
 
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the best way to cut foam is with an electric carving knife but few people own them 

you would just cut the hole out and then cut the piece in half or what ever depth you want 

but what i would do is buy a new case, that one is cheap one in the first place you can do better 

Plano had great case but stopped making them, there DXL line was made for 50 years under the Doskocil and then Gun Guard, they are Ebay but not like they use to, i own maybe 20 or more 
 
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I made a hot wire foam cutter. I bought a 2.5amp USB charger as power source and a hacked up USB cable to apply the power to the wire. I used Nichrome wire as the "blade." A nice thing to add is some kind of foot switch to cut the power to the wire when making turns. I'm sure you could do it without a switch, but I found that the table had to be bigger to keep from hanging the foam up on the table edges. If the cutting gets stalled and the power is still on, you'll screw up the cut.

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I bought a 2" thick polyurethane foam sheet and cut it to fit my case. I outlined the Matador using a dry erase marker. The lines will wash off with water.

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The cutting part was straightforward after a little practice. I cut as close to the inside edge of the line as I could.

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The gun fits really well.

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