Custom Foam Lining for Carrying Case

[AKPilot]

I've got an interesting idea and was wondering if I could make it into reality.

I've got a aluminum carrying case for an r/c transmitter. I'd like to customize the foam insert to hold exactly what I'd like. Does anyone know of a way, or a place, that can make custom foam inserts?

I remember about six years ago in the Air Force we did this once but can't, for the life, of me figure out how or where one of my guys did it.

 

[RangerStl]

I use seat cushion foam blocks from Hobby Lobby and cut it myself.

The urethane will eventually start to degrade, but that usually takes 15 to 20 years.

 

[new2hpr]

You could go "semi-custom" with something like the pick-n-pluck foam that Pelican uses in their cases. Pelican supplies a lot of military cases. Full custom inserts are very expensive, and only worth it in large volumes.

-Ken

 

[Scott Evil]

The Pick-n-Pluck does work pretty well. I have a double pistol case that I custom plucked to house some RMS casings. I did have to glue a few squares back as I wasn't careful enough.

That said, a few years ago I perused a hobby shop that specialised in D&D and miniature war gaming type stuff. Off in the back of the shop they had all kinds of cases and a stack of (10" x 20"?) sections of the pick n pluck style foam.

PRE POST EDIT [Searched and found this, mid yammer] https://www.nextag.com/pluck-foam/products-html?nxtg=57550a240526-63BCBB2EBA8C4E31

Scott

 

[Viperfixr]

I've got an interesting idea and was wondering if I could make it into reality.

I've got a aluminum carrying case for an r/c transmitter. I'd like to customize the foam insert to hold exactly what I'd like. Does anyone know of a way, or a place, that can make custom foam inserts?

I remember about six years ago in the Air Force we did this once but can't, for the life, of me figure out how or where one of my guys did it.

Air Force maintainers mostly use razor blades cutting sheet foam after outlining the part. Now, we mostly buy the foam pre-cut and shadowed from the tool vendor with laser etched tools to boot--much easier!

 

[hcmbanjo]

Years ago I had to get foam to form fit around a small banjo.

I went to the "custom" foam place and went into the back room where they cut the foam. They were using electric carving knives, the same kind you would use to carve a turkey!
It cut through the foam easy and the finished lines were pretty clean.

This was the foam (not styrofoam) like you would use in a very firm pillow.
The kind of foam you could crush in your hand, release it and it would open back to it's original shape. That was in the early 1980s, I'm still using it.

Now I use the "pick and pluck" style of foam. But the option of the softer foam and electric knife could be much cheaper.

 

[Handeman]

My Mom did upholstery for years and I helped out. Replacing cushions required cutting and gluing foam all the time.

You can get foam at most fabric stores in varying thicknesses. An electric knife will cut it great. Use contact cement to glue it together. 3M spray 77 works great if you can keep if off the places you don't want to glue. Otherwise, any good contact cement will work just fine.

I've made foam liners for telescopes, all my motors, etc. For the motors, I used a 1" flat piece and glued 2" pieces in place to hold the motors (24 - 38 mm) then another 1" piece laid over the top to fill the space in the case.