customizing a gun case (foam cutting)

[nightrunner]

i am trying to find a good, high-quality aluminum handgun case for my XDM-9.

what i have come up with is the case by Kalispel at midway

http://www.midwayusa.com/viewProduct/?productNumber=142031

and i am assuming that it will have the same foam as this one

http://www.midwayusa.com/viewProduct/?productNumber=630838

my question is, will the type of foam that comes in this case be able to be custom cut to fit my gun and accessories in the case. it says the foam is approx. 2" thick which should be enough, i would think, for the gun, etc. to be covered.

to clarify what i am wanting, is an aluminum case with solid foam that i can custom cut to fit the gun and extra mags in the configuration that i am wanting. if you have seen the inside of an XDm factory case, that is what i want only with my placement and arrangement.

can i cut(or have someone more experienced) the type of foam that is in this case and make it look professional or will i need something else? also if anyone knows where i can get the foam cut at, i would appreciate it, i tried it on a tool case and i cant do it well.

[TripleDigitRide]

If you have the proper tools, you can do it yourself. You'll need a hot knife. You may be able to pick one up at a local hobby shop. I have seen someone use a soldering gun pencil type) to get the same results. They were not "factory" results, but still pretty darn good.

If that is not an option for you, you may be able to find a shop that has such tools, but I can't think of anyone.

[nightrunner]

im guessing a hot knife is a specialty tool and not a regualr cutting knife at a high temperature

i wonder if herogear would be capable of cutting the foam assuming i had the case and a layout of what i wanted

[TripleDigitRide]

im guessing a hot knife is a specialty tool and not a regualr cutting knife at a high temperature

i wonder if herogear would be capable of cutting the foam assuming i had the case and a layout of what i wanted

I hot knife is similar to a soldering gun, only with a knife blade.

If it were me, I would trace the gun, mags, etc with a black marker, and use a pencil-type solder iron.

[nightrunner]

so essentially you would be burning the foam apart instead of cutting it?

[56FordGuy]

A friend of mine did an excellent job cutting foam for his gun case with an electric bread knife. You might try that.

[TripleDigitRide]

so essentially you would be burning the foam apart instead of cutting it?

Yes. That is the best way to explain it. If you search around the Internet, you'll see that that's how most of the pro foam cutters/sculptures do it. Hot knife or Hot wire.

[VERO1]

+1 on the electric knife, my parents reupholster furniture and thats the only thing they use. Go slow and practice a little on some scrap material first. You might surprise yourself!

[bukowski548]

Pelican cases suggest you use an electric bread knife on their foam. I've had pretty good luck with that. I've never heard of the hot knife, may have to try that next time. Anybody know how much they run?

buk

[nightrunner]

thanks for the info guys, i will have to get a very cheap tool case to try on first but im hoping the electric knife works

[Guest bluecanary25]

Overthinking this......

old laptop case, old discarded seat cushion, exacto knife, black marker.

Spaced apart, I fit 2 pistols, spare mag for each and still have room for ammo in outer pockets.....

and who gives a second glance at old cloth laptop cases??

Obviously it only has some old junky laptop......not worth stealing...

Well, it works for me.....

[E4 No More]

I used a single edge razor blade.

[Guest Linoge]

I recommend an electric, reciprocating knife, as some people use for bread and whatnot. However, before you do so, I would stronly advise laying out the items on the foam as you would want them, and then outlining them in chalk. Then cut inside the chalk outline (you want this snug after all), and off you go. For fine work, use a standard, unpowered bread or utility knife, and you will be good to go.

[Bassoneer]

Here's one I am working on using the hot wire foam cutting tool. I got the cutting device at AC Moore in the foam section, but it ain't the greatest...I had to rig it up on my table out on the deck with duct tape to hold it in place vertically. The best would be one of the home-made tables with a longer wire - there are lots of instructions on the internet and you need some wire and maybe a transformer from Radio Shack, but I would think that would give the best results. This little task has been tedious and has resulted in a couple of not-so-great attempts. Good luck. B

[Bassoneer]

One more tip - it is hard to get the outline of the guns on the foam, so after several failed attempts, I read on one internet site about a person who took a drafting triangle and taped a pencil to one side to keep it perfectly vertical, then traced the outline of the guns on paper. After making the outline, you have to draw another parallel line INSIDE the original line 1/2 the thickness of the pencil. My pencil was a good old #2 pencil that was 1/4" thick, so I put a second line 1/8" inside the outline...that is the actual shape of the gun. I carefully cut those patterns out and used my wife's straight pins to hold them down to the foam so I could cut around them...Good luck again, B

[peejman]

The hot wire is the best tool, depending on the type of foam. Some foams cut nicely, some just melt into goo. If you're cutting with a knife, instead of using 2" thick foam, get 2 pieces of 1" thick. You can cut completely through the 1" foam and lay another uncut piece under it. A few dabs of glue will hold the two pieces together. Again, you have to find the right glue as some glues with dissolve the foam.

[I_Like_Pie]

I would just like to find a source of foam that doesn't fetch more than the price of the case itself.

Picked up a hard case from wal-mart for $8 and cut it for my target pistol. Would like to have an extra insert for my revolver and the cheapest price I could find for eggshell foam was $10. Some things just don't add up!?!?

[MacGyver]

Forget the electric knife and hot knife. With 2" foam like is typical in most pistol cases and in my Pelican 1750 you don't need them. Not that you can't use them. It's just easy to screw it up - fast. Trace your weapon and accessories as you want them, then just cut it out with a large x-acto knife. You just depress the foam as you are cutting it, and the knife slides right through.

[Bassoneer]

Forget the electric knife and hot knife. With 2" foam like is typical in most pistol cases and in my Pelican 1750 you don't need them. Not that you can't use them. It's just easy to screw it up - fast. Trace your weapon and accessories as you want them, then just cut it out with a large x-acto knife. You just depress the foam as you are cutting it, and the knife slides right through.

You must be a cardiologist or plastic surgeon. My first two attempts using x-acto's are in the garbage can next to me. B

[MacGyver]

You must be a cardiologist or plastic surgeon. My first two attempts using x-acto's are in the garbage can next to me. B

Forensic Specialist. I really didn't have any problem with it. I used a super long blade, and a careful sawing action. The Pelican foam is pretty dense. Maybe more dense than what you are using. That definitely made it easier.

Your hot wire attempts look pretty good.

There's probably a business in there somewhere. I'm imaginging a large format scanner that will take an outline of the weapon and accessories. A cad program to lay them out, and a big CNC router to cut the foam.

[Guest jackdm3]

Slightly on topic, for your really thick pieces, it's fun to try a copper coathanger clamped between the the ground and the electrode of a 220V welding machine. Butter.

[Bassoneer]

Forensic Specialist. I really didn't have any problem with it. I used a super long blade, and a careful sawing action. The Pelican foam is pretty dense. Maybe more dense than what you are using. That definitely made it easier.

Your hot wire attempts look pretty good.

There's probably a business in there somewhere. I'm imaginging a large format scanner that will take an outline of the weapon and accessories. A cad program to lay them out, and a big CNC router to cut the foam.

I think you're right. I got the foam at a foam and fabric outlet in Knoxville, and it is spongy open-cell foam. The closed cell stuff is stiffer and would probably be easier to cut - it is like what comes in the Springfield XDm cases. I may actually try some of that stuff in the future...I've heard the lightweight open-cell stuff holds moisture/oil/dirt and the closed-cell is the way to go. Later, B

[mikegideon]

I think you're right. I got the foam at a foam and fabric outlet in Knoxville, and it is spongy open-cell foam. The closed cell stuff is stiffer and would probably be easier to cut - it is like what comes in the Springfield XDm cases. I may actually try some of that stuff in the future...I've heard the lightweight open-cell stuff holds moisture/oil/dirt and the closed-cell is the way to go. Later, B

I had a bunch of acoustic foam cut to size years ago by a place that specialized in foam cutting. They recommended lubricating the knife with silicone before making any cuts, so the foam doesn't distort while you're cutting.