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View Full Version : Weapons Case Hotwire Foam Cutting - 21 Pix (Diagram Added 6/20/12)


Elwood_Blues
05-31-2012, 9:47 PM
Mods, Admins, I really wasn't sure where to post this and figured this was an appropriate section. If it is not, sorry, please move it to where it belongs. Thanks!


So I got this idea from ARFCOM and decided to do it myself. There is an extensive thread on that site, but I figured I'll post my version here as there are many members who don't visit ARFCOM as much as Calguns. I used a Pelican case, but you can use whatever tickles your fancy with high-density foam.

If you decide to do this, take your time for best results. I spread this project over few days as time allowed and it literally took hours each time.

Here is my primitive hot wire foam cutter:

25V transformer from Radio Shack - $14
Light Dimmer Switch, Home Depot - $5
Brass rod 1/4"x3', some metal supply joint - $8
Nichromium wire, ebay - >$2
Lumber - free lefrovers from friends
Total Cost - >$29

After cutting, I learned that the I need to shorten the length of the wire by at least half. It is due to the fact that it tends to "drag" and if it's shorter, there is less of a chance for a f**k up with a shorter and tenser wire.

http://i31.photobucket.com/albums/c382/mustangphil302/Foam%20Cutting/DSC_0134.jpg
http://i31.photobucket.com/albums/c382/mustangphil302/Foam%20Cutting/DSC_0132.jpg

Now trace around your weapon, or whatever it is you're putting in your case.

http://i31.photobucket.com/albums/c382/mustangphil302/Foam%20Cutting/DSC_0078.jpg
http://i31.photobucket.com/albums/c382/mustangphil302/Foam%20Cutting/DSC_0079.jpg


Once you're done, clean up your lines with a straightedge.

http://i31.photobucket.com/albums/c382/mustangphil302/Foam%20Cutting/DSC_0080.jpg

When finished, it should look somewhat like this.

http://i31.photobucket.com/albums/c382/mustangphil302/Foam%20Cutting/DSC_0081.jpg

Elwood_Blues
05-31-2012, 9:48 PM
At this point it’s a good idea to make yourself a drink, you’ll need it, trust me on this one.

http://i31.photobucket.com/albums/c382/mustangphil302/Foam%20Cutting/DSC_0082.jpg


It’s also helpful to measure what you traced in few spots to compare with original to make sure you’re on target. I feel that if it’s a 1/16” or so short, it’s actually good to keep things tight.


http://i31.photobucket.com/albums/c382/mustangphil302/Foam%20Cutting/DSC_0083.jpg


Once you got everything on paper (I used poster board) it’s time to cut it all out. I used an exacto knife and straightedge, but sharp scissors will work just fine.


In my case, I had a pretty simple set up in mind, so there aren’t that many options for me. However, now it is time to let your imagination wonder. If you have one rifle with multiple uppers, lowers, accessories, etc., lay it all out. If you have a bunch of accessories, it is helpful to take a picture of each set up you come up with and once you explored all possibilities, just scan through your pix and pick what works best for you.


http://i31.photobucket.com/albums/c382/mustangphil302/Foam%20Cutting/DSC_0100.jpg
http://i31.photobucket.com/albums/c382/mustangphil302/Foam%20Cutting/DSC_0107.jpg



Once you’re happy with your set up, lay the first piece you’ll cut and hold it in place. I had pushpins, so that’s what I used, but thumbtacks will work just as good.

http://i31.photobucket.com/albums/c382/mustangphil302/Foam%20Cutting/DSC_0108.jpg

Cut a pilot hole, sharp knife is helpful at this point as razor is not big enough to cut all the way through this piece of foam, but that’s all I had at the moment and didn’t feel like getting a knife.


http://i31.photobucket.com/albums/c382/mustangphil302/Foam%20Cutting/DSC_0110.jpg

Elwood_Blues
05-31-2012, 9:48 PM
Feed the wire through the pilot hole, attach it back on the rod and turn your contraption on.

http://i31.photobucket.com/albums/c382/mustangphil302/Foam%20Cutting/DSC_0111.jpg


It is good to have some scrap foam so you can adjust the heat on the wire. You don’t want it glowing red as that will burn right into your paper template. Just play around at this point with a spare piece of foam.

Once you have the heat dialed in, start cutting. I found that is helpful to have support on both ends of the cutter to keep the foam from bending down once it leaves the cutting surface. Nice and slow around the template.

http://i31.photobucket.com/albums/c382/mustangphil302/Foam%20Cutting/DSC_0113.jpg


When you complete the cut around the template back to the pilot hole, you probably won’t be able to cut any further without checking first how well you did and fit your piece into the cutout.

Once you’re pleased with your work, you might want to put the “plug” back into the hole before you start the next cutout to try to keep the entire foam more stiff.


http://i31.photobucket.com/albums/c382/mustangphil302/Foam%20Cutting/DSC_0124.jpg


The last step is to cut some of the plugs to appropriate thickness to compensate for the item’s width. In my case I only cut the bolt plug and one for the Glock. I just used a piece of wood as guide to make my cut straight.


http://i31.photobucket.com/albums/c382/mustangphil302/Foam%20Cutting/DSC_0125.jpg
http://i31.photobucket.com/albums/c382/mustangphil302/Foam%20Cutting/DSC_0126.jpg


Insert the plug back into the hole and you’re pretty much done. Note the difference in depth of the hole where there is a plug.

http://i31.photobucket.com/albums/c382/mustangphil302/Foam%20Cutting/DSC_0128.jpg

Elwood_Blues
05-31-2012, 9:49 PM
Now put all your items in the case and enjoy!

http://i31.photobucket.com/albums/c382/mustangphil302/Foam%20Cutting/DSC_0127.jpghttp://i31.photobucket.com/albums/c382/mustangphil302/Foam%20Cutting/DSC_0130.jpghttp://i31.photobucket.com/albums/c382/mustangphil302/Foam%20Cutting/DSC_0131.jpg


I kept the templates for future projects. I'm also keeping the plugs to use if I'm not putting some of the items into the case to keep things tight.



EDIT: The Diagram

As you can see, I'm not a graphic designer, nor an electrical engineer. This is a guide only, not directions. I WILL NOT be responsible for any injury, damage, death, or whatever else you can think of.


http://i31.photobucket.com/albums/c382/mustangphil302/Foam%20Cutting/Mywiring.jpg

rkt88edmo
05-31-2012, 10:10 PM
Nice results.

NorCal Einstein
05-31-2012, 10:14 PM
Very nice job! Looks super clean!

BANG BANG
05-31-2012, 10:31 PM
cool write up, I will be needing this thread soon !!

Ubermcoupe
06-02-2012, 11:20 AM
Nice how-to! Good job OP. :)

WILDMAN442
06-02-2012, 11:28 AM
Very cool man!

Some day when I get me a high speed pelican case I'll have to do this.

Justin

Thomas1190
06-02-2012, 11:48 AM
Very, very nice! Great job!

ChaneRZ
06-02-2012, 12:03 PM
nice job!

Press Check
06-02-2012, 12:07 PM
Good work.

tpuig
06-02-2012, 8:56 PM
Absolutely beautiful. I wish you lived on my block...

Noonanda
06-02-2012, 9:08 PM
nice, where did you get that foam at?

fighterpilot562
06-02-2012, 9:44 PM
Looks awesome!

Elwood_Blues
06-03-2012, 12:31 AM
Thanks for all the complements everyone, I really appreciate it.

nice, where did you get that foam at?

Came with the case. I also have a spare center piece that I got on the trade so I can cut a different set up.

voiceofreason
06-03-2012, 5:24 AM
Since you've already invested in building the equipment and have some experience now, consider doing a few freebies for Calgunners to get some feedback, then maybe charge for the service for a moderate/reasonable fee.

Myself, I would not want to do this as a project, as I'd simply outsource the cutting of the foam over DIY.

Websites are cheap to develop and maintain. Stick with locals that aren't shipping anything to you.

I'd guess within 6 months you could have about 10 cases a week easy if you "spread the word" right.

Brandon04GT
06-03-2012, 6:05 AM
Very nice. You definitely put some good effort into that.

Casual_Shooter
06-03-2012, 8:51 AM
Nicely done. This has been on my To-Do list for some time.

BraveUlysses
06-03-2012, 9:01 AM
Exceptional job! Well done. (Much much better than my attempt. :) )

ENVYGREEN
06-03-2012, 9:11 AM
Great job! I'm doing this some day

SarStyle
06-18-2012, 4:10 PM
Well I guess I will let you build mine....when can I expect it on my doorstep?

Hecktic
06-18-2012, 4:30 PM
:Ivan: Just kidding... kind of ;) It's awesome and now I know what I'm going to be doing for my summer vacation :)

Cactus_Tim
06-18-2012, 5:46 PM
Should I get in line?
Could use a little foam cutting to fit my Streamlight TLR-4
How many beers do you charge?

GREASY357
06-18-2012, 6:09 PM
very helpful, will be using this soon thanks!

223Devil
06-19-2012, 8:18 AM
Tagging.

Quinc
06-19-2012, 8:31 AM
Great write up! I liked the pic with the Vodka! :D

Agustav
06-19-2012, 2:49 PM
I would like to know where can I purchase some foam as well... :notworthy:

alfred1222
06-19-2012, 2:58 PM
Ya im tagging this one, it would actually be a good sticky somewhere, like the how to section

em9sredbeam
06-19-2012, 3:05 PM
Thats pretty cool man, thanks for sharing.

Duranimal
06-19-2012, 4:14 PM
very cool great job. I tend to be a bit messier with stuff like this. Mine would look like I took a hacksaw to it.

weekend_plinker
06-19-2012, 6:46 PM
I would like to know where can I purchase some foam as well... :notworthy:

foam supplies LA

http://millerfoam.com/

http://packaging.advancedfoam.com/polyurethane/

http://www.foammart.com/

or call people on this list

http://www.yellowpages.com/los-angeles-ca/polyurethane-foam

thaiphob25
06-19-2012, 7:01 PM
Great work!

joefrank64k
06-19-2012, 7:53 PM
Excellent write-up! And I love the mix of old and new in the case!

bodger
06-19-2012, 7:56 PM
Nice work.

Mikeed
06-19-2012, 9:35 PM
Thanks for the help cant wait to try it.

finyllw
06-21-2012, 2:15 PM
Just a quick note here. I called Miller foam, the first contact on the list that "weekend plinker" listed (Thanks for that) and I talked to a guy named John.

He suggested "Extra Firm High Density Polyurathane (sp) Foam". It comes in dark charcoa, is chemical resistant, comes in many different thicknesses up to 2" thick. Sheets are 24" by 72" 2" thick are $36.00, 1" thick sheets are $18.00.

They are in South El Monte.

I am in the process of building a foam cutter, just in the begining stages of tracking things down. I'll keep you all posted on how things go. Heading out right now to get the Nichromium wire.

A big thanks to Elwood Blues for posting his projects, information, and wiring diagram.

Milspec714
06-21-2012, 2:29 PM
Outstanding.. very nice

finyllw
06-22-2012, 2:55 PM
Just a quick note here. I called Miller foam, the first contact on the list that "weekend plinker" listed (Thanks for that) and I talked to a guy named John.

He suggested "Extra Firm High Density Polyurathane (sp) Foam". It comes in dark charcoa, is chemical resistant, comes in many different thicknesses up to 2" thick. Sheets are 24" by 72" 2" thick are $36.00, 1" thick sheets are $18.00.

They are in South El Monte.

I am in the process of building a foam cutter, just in the begining stages of tracking things down. I'll keep you all posted on how things go. Heading out right now to get the Nichromium wire.

A big thanks to Elwood Blues for posting his projects, information, and wiring diagram.

I bought a transformer from a local electronics shop, 120ac to 24v dc. Hooked it up and didn't get any heat from the wire, and the ac side went open circuit after 5 minutes. I researched EB's op, he didn't mention ac/dc thing. Went online to Radio Shack, found thier transformer, and picked one up. It's a 120ac to 25vac. I didn't think this would work. I got back to the shop and much to MY suprise (EB already knew this) is worked just fine. I actually cut some foam. I couldn't find any 24 ga Nichromium wire locally, I did find 20ga. It's a little thicker but it has worked ok on my test. Finding the brass rod is a challenge, looks like Orchard Supply might have some. I'll let you know asap. Next up is to build a frame. So far i have $40 into this, but I am excited about the possibilities. I'm also thinkin about loaning/renting this thing out in case anybody wants to do thier own foam cutting. I'll keep you all posted.

Radio Shack part number for the transformer is 273-1512B

Elwood_Blues
06-22-2012, 11:41 PM
Again, thanks for all the positive comments!

Well I guess I will let you build mine....when can I expect it on my doorstep?

Whenever you drop a case at my doorstep with whatever you want cut out :D
Should I get in line?


You already are ;)
Great write up! I liked the pic with the Vodka! :D

Thanks, gotta have it!

I bought a transformer from a local electronics shop, 120ac to 24v dc. Hooked it up and didn't get any heat from the wire, and the ac side went open circuit after 5 minutes. I researched EB's op, he didn't mention ac/dc thing. Went online to Radio Shack, found thier transformer, and picked one up. It's a 120ac to 25vac. I didn't think this would work. I got back to the shop and much to MY suprise (EB already knew this) is worked just fine. I actually cut some foam. I couldn't find any 24 ga Nichromium wire locally, I did find 20ga. It's a little thicker but it has worked ok on my test. Finding the brass rod is a challenge, looks like Orchard Supply might have some. I'll let you know asap. Next up is to build a frame. So far i have $40 into this, but I am excited about the possibilities. I'm also thinkin about loaning/renting this thing out in case anybody wants to do thier own foam cutting. I'll keep you all posted.

Radio Shack part number for the transformer is 273-1512B

Yeah, sorry, as I mentioned in post 3 when I posted the diagram, I'm not an electrical engineer, I just forgot. Getting a brass rod was not easy, I found it in a industrial metal supply store.

Jeff L
06-22-2012, 11:57 PM
Awesome! Should be a sticky.

trg-s338
06-23-2012, 11:13 PM
tag

negolien
06-24-2012, 4:26 AM
Since you've already invested in building the equipment and have some experience now, consider doing a few freebies for Calgunners to get some feedback, then maybe charge for the service for a moderate/reasonable fee.

Myself, I would not want to do this as a project, as I'd simply outsource the cutting of the foam over DIY.

Websites are cheap to develop and maintain. Stick with locals that aren't shipping anything to you.

I'd guess within 6 months you could have about 10 cases a week easy if you "spread the word" right.

I +1 this as a little side work for extra cash.

jmlivingston
06-24-2012, 8:08 AM
Mods, Admins, I really wasn't sure where to post this and figured this was an appropriate section. If it is not, sorry, please move it to where it belongs. Thanks!



This is pretty good stuff, I've moved it over to the "CGN Best Of" section.

John

wchutt
06-24-2012, 3:23 PM
Thank you for help on trouble shooting when I did this. I skipped step one in the second post... never again!
I used a battery charger from Harbor Freight, .030 carbon steel welding wire, a dimmer switch and a spring to keep tension on the wire, Mine looks a little more red neck.
Got my closed cell foam here: http://www.closedcellfoams.com/polyethylene.html

Anyone in the Redding area is welcome to use it!

http://i1138.photobucket.com/albums/n537/wchutt/IMG_0010-1.jpg

http://i1138.photobucket.com/albums/n537/wchutt/IMG_0003.jpg

joefrank64k
06-24-2012, 5:05 PM
Thank you for help on trouble shooting when I did this. I skipped step one in the second post... never again!
I used a battery charger from Harbor Freight, .030 carbon steel welding wire, a dimmer switch and a spring to keep tension on the wire, Mine looks a little more red neck.
Got my closed cell foam here: http://www.closedcellfoams.com/polyethylene.html

Anyone in the Redding area is welcome to use it!

http://i1138.photobucket.com/albums/n537/wchutt/IMG_0010-1.jpg

Clever method of maintaining tension on the wire! Good stuff!

Casual_Shooter
06-24-2012, 6:08 PM
Clever method of maintaining tension on the wire! Good stuff!

+1. I like the way you used the spring.

Elwood_Blues
06-25-2012, 9:47 AM
This is pretty good stuff, I've moved it over to the "CGN Best Of" section.

John

Thanks!

Thank you for help on trouble shooting when I did this. I skipped step one in the second post... never again!

Told ya:D

I used a battery charger from Harbor Freight, .030 carbon steel welding wire, a dimmer switch and a spring to keep tension on the wire, Mine looks a little more red neck.

Looks good man! And as others said, the spring is a great idea. I was going to put one at the end of the rod.

Clever method of maintaining tension on the wire! Good stuff!

+1. I like the way you used the spring.

Exactly right.

finyllw
06-25-2012, 11:18 AM
Dammit, back to the hardware store. Thanks for the spring idea.

finyllw
06-25-2012, 11:30 AM
Here's the first project I will be practicing on.

http://i1000.photobucket.com/albums/af125/dammitgang/DSCF0007.jpg

http://i1000.photobucket.com/albums/af125/dammitgang/DSCF0008.jpg

Elwood_Blues
06-25-2012, 2:23 PM
I like the First Aid Kit idea, that's awesome. It should be pretty easy. Post results, chop chop :D

Dark Sky Solutions
06-25-2012, 2:36 PM
Elwood,

You beat me to it brother!!!! Very nice though. I found a foam cutter at a craft store that ran on batteries. Not even close enuff to the power/heat i needed so I hooked up an old Tattoo gun power source with the foot pedal to it. Works like a charm now. I think I will transform the handheld version to a table top like yours.

Great write up.

SNCaliber
06-25-2012, 2:48 PM
damn those are some clean cuts, very nice!

NorCal1911Fan
06-26-2012, 8:09 PM
Wow very nice.. Thanks for the write up. Will be building one and putting it to use soon.

Bigben
06-30-2012, 8:09 AM
Check out hobby stores for the nichrome wire( Hobbyyown USA or model train stores). They sell a hand held foam cutter and replacement wire. Lots of foam cutting when building model train terrain, tabletop wargame terrain, or diorama terrain.

Dark Sky Solutions
07-01-2012, 9:05 AM
Well, thanks to you Elwood, I spent half of yesterday turning my little hand held into this. I went by hobby people and didn't find any of the wire so I tried some various types of wire I have in the shop. It all failed and I ended up using the piece that was on my hand held foam cutter. It is a little short so I only have 4.5" of clearance right now. When I find some more wire it will give me 5.5" of clearance to cut foam. I think that is Enuff clearance for just about anything I will be cutting. The rod I used is the one from my hand held. I rebent it into the shape I wanted, threaded the end of it and threaded a piece of aluminum to act as a nut and base for it. My power source is a tattoo gun power supply and hooks up nicely with a variable power selector.

http://img.tapatalk.com/4882a44c-7479-c2de.jpg

http://img.tapatalk.com/4882a44c-74a7-214c.jpg

http://img.tapatalk.com/4882a44c-750f-81ff.jpg

http://img.tapatalk.com/4882a44c-752f-5b32.jpg

EB, thanks for the inspiration brother. I like it, I can't wait to get my foam in I ordered to start making a bunch of stuff.

Dark Sky Solutions
07-01-2012, 1:18 PM
Well I couldn't wait so I found some scrap foam and made a smaller case for a couple pistols

http://img.tapatalk.com/4882a44c-b077-a67f.jpg

http://img.tapatalk.com/4882a44c-b0ae-9dc4.jpg

Elwood_Blues
07-01-2012, 6:14 PM
Well, thanks to you Elwood, I spent half of yesterday turning my little hand held into this. I went by hobby people and didn't find any of the wire so I tried some various types of wire I have in the shop. It all failed and I ended up using the piece that was on my hand held foam cutter. It is a little short so I only have 4.5" of clearance right now....

...EB, thanks for the inspiration brother. I like it, I can't wait to get my foam in I ordered to start making a bunch of stuff.

You're welcome, I think it can become addictive :D

Here is where I got my nichrome wire, it came fast;
http://www.ebay.com/itm/12-feet-24-guage-Resistance-Nichrome-Wire-/251095990978?pt=LH_DefaultDomain_0&hash=item3a767cc2c2#ht_606wt_1185

Well I couldn't wait so I found some scrap foam and made a smaller case for a couple pistols

http://img.tapatalk.com/4882a44c-b077-a67f.jpg

http://img.tapatalk.com/4882a44c-b0ae-9dc4.jpg

Looks good!

nutzkicker617
07-01-2012, 10:16 PM
great tips in this thread.

if you need more space and support, try out this setup.

http://snipershide.com/forum/ubbthreads.php?ubb=showflat&Number=2961775#Post2961775

Whiplash Actual
07-02-2012, 8:50 AM
Great work!

mtsul
07-04-2012, 1:50 PM
What case is that? And what kind of foam?
Awesome job!

sarabellum
07-04-2012, 2:54 PM
Great work! Remember, folks, ventillation. If you are worried about burning your template, you can always use chalk to trace around the template onto the foam, and then remove the template. Best regards.

Dark Sky Solutions
07-04-2012, 3:24 PM
What case is that? And what kind of foam?
Awesome job!

Not sure if u are asking me or Elwood B.

My case is the Hardig Storm M2100
http://img.tapatalk.com/4882a44c-c209-8e94.jpg

My foam is just left overs I have from pelican cases. This one was egg crate.

http://img.tapatalk.com/4882a44c-c239-5f2f.jpg

If I flip it over like that it conceals them a bit better. when I putt he other piece of foam on it.

http://img.tapatalk.com/4882a44c-c25d-bffc.jpg

Normally I use this case for my DSLR cameras on trips camping or over the water to protect them. This case and hack job on the foam kept my Nikon safe and functioning dying a 6 month trip to some not so nice places in Africa.
http://img.tapatalk.com/4882a44c-c27a-037e.jpg

Elwood_Blues
07-04-2012, 9:01 PM
What case is that? And what kind of foam?
Awesome job!

If you were referring to Doc's, he already answered. I used Pelican 1750 with foam that came with it. Thanks!

Great work! Remember, folks, ventillation. If you are worried about burning your template, you can always use chalk to trace around the template onto the foam, and then remove the template. Best regards.

You have to keep the template there if you want straight lines. I just can't see anyone cutting it perfectly straight freehand. If you're burning the template, you most likely have the wire too hot. When set correctly, it will cut through the foam with minimal effort, while not damaging the template, which btw, can be easily replaced. ;)

Davisje011
07-06-2012, 10:03 AM
Hobbypeople carries brass tubing for projects, there are 15 locations in socal.
www.hobbypeople.net

They also carry the foam Cutters, but i'd prefer a table top like this one to a handheld anyday.

What i'm really looking for is a way to felt line the top, without scissors. any ideas?

Quinc
07-06-2012, 11:41 AM
Do you think the wire out of an old toaster would work?

finyllw
07-06-2012, 3:30 PM
I would think it is the right kind of wire, just might be a little thick. If so, you might want to make your template a little on the small side.

Elwood_Blues
07-07-2012, 8:26 AM
Do you think the wire out of an old toaster would work?

Yes, it will work. In fact, that's what I used before I ordered 24 gauge from ebay. The problem with a toaster wire, is that it's flat, not round. I got the wire from a guy on ebay that has all kinds of different thicknesses, it's cheap and he ships fast.

http://www.ebay.com/itm/10-feet-21-guage-Resistance-Nichrome-Wire-/251099059828?pt=LH_DefaultDomain_0&hash=item3a76ab9674

Footb82
07-09-2012, 1:37 PM
I just bought 12 feet of 24 guage from the guy on eBay. Dont think all 12 feet is needed for this project. If someone is looking to build one of these I would be happy shipping 2' at a time to people. PM your info.

finyllw
07-09-2012, 3:29 PM
So the last couple of weeks have been VERY busy for me. I had a regular monthly Cowboy action shoot, 8 stages, about 24 rounds per stage. Finished cleaning the guns and making bullets Saturday night around 11:30pm. Sunday was hot, finished the match, did ok, 1st in my class. Tues night out in the shop getting ready for a special 4th Of July Cowboy shoot. 5 stages 24 rounds each. Did not so good. Wed night my SIL came over, we loaded about 100 rounds of .223. During that time the lights in my shop started flickering and actually went out a coule times. Noticed my patio lights freaking out as well. Reset the breakers, all was ok. Thursday night more electrical problems, this time smoke started rolling out of a socket. So gathered up all powder, primers loaded ammo and moved it all to garage. Unplugged everything, shut off breakers called electrician. Saturday he went through everything found out my shop was wired WAY wrong. NOTE: I bought this place 2 years ago, shop was setup by other guy.

Anyway, my electrical guy got things working, needs to come back to rewire from the main box to the sub box, then from sub box to shop YEAH!!! $1K +. But things were working for now. So I go out and finish my foam cutter. SEE PICS. Got 3/4 done on first piece, lights dimmed, heard a POP, then smoke started rolling out of ......FOAM CUTTER. I think my transformer blowed up. Not sure why, but I may not have enough resistance in the curcuit, maybe pulling too many amps overheating the transformer. I'm bummed I couldn't at least have finished one project.

I too forgot step number 2, all I have is tequilla. Yuch. If any of you have the chance, would you please check resistance with transformer wires unplugged from Nichrome wire all the way back to transformer. The tranformer is rated at 2 amps, but I'm thinking if resistance is low, like 2 ohms, at 24v I have 12 amps going throught the circuit. WAY TOO MUCH.

http://i1000.photobucket.com/albums/af125/dammitgang/DSCF0016.jpg
http://i1000.photobucket.com/albums/af125/dammitgang/DSCF0018.jpg
http://i1000.photobucket.com/albums/af125/dammitgang/DSCF0021.jpg

The last picture shows the rough edges, I think the wire was cooling off or I was pushing the foam through too fast. Also as a reminder, the foam will flex and distort if you push it too hard. SLOW DOWN. DON'T FORGET STEP 2!!

joefrank64k
07-09-2012, 3:37 PM
So the last couple of weeks have been VERY busy for me. I had a regular monthly Cowboy action shoot, 8 stages, about 24 rounds per stage. Finished cleaning the guns and making bullets Saturday night around 11:30pm. Sunday was hot, finished the match, did ok, 1st in my class. Tues night out in the shop getting ready for a special 4th Of July Cowboy shoot. 5 stages 24 rounds each. Did not so good. Wed night my SIL came over, we loaded about 100 rounds of .223. During that time the lights in my shop started flickering and actually went out a coule times. Noticed my patio lights freaking out as well. Reset the breakers, all was ok. Thursday night more electrical problems, this time smoke started rolling out of a socket. So gathered up all powder, primers loaded ammo and moved it all to garage. Unplugged everything, shut off breakers called electrician. Saturday he went through everything found out my shop was wired WAY wrong. NOTE: I bought this place 2 years ago, shop was setup by other guy.

Anyway, my electrical guy got things working, needs to come back to rewire from the main box to the sub box, then from sub box to shop YEAH!!! $1K +. But things were working for now. So I go out and finish my foam cutter. SEE PICS. Got 3/4 done on first piece, lights dimmed, heard a POP, then smoke started rolling out of ......FOAM CUTTER. I think my transformer blowed up. Not sure why, but I may not have enough resistance in the curcuit, maybe pulling too many amps overheating the transformer. I'm bummed i couldn't at least have finished one project.

I too forgot step number 2, all I have is tequilla. Yuch. If any of you have the chance, would you please check reisitance with transformer wires unplugged from Nichrome wire all the way back to transformer.

http://i1000.photobucket.com/albums/af125/dammitgang/DSCF0016.jpg
http://i1000.photobucket.com/albums/af125/dammitgang/DSCF0018.jpg
http://i1000.photobucket.com/albums/af125/dammitgang/DSCF0021.jpg

The last picture shows the rough edges, I think the wire was cooling off or I was pushing the foam through too fast. Also as a reminder, the foam will flex and distort if you push it too hard. SLOW DOWN. DON'T FORGET STEP 2!!

That's better! :)

finyllw
07-09-2012, 3:46 PM
Way better, Thanks.

finyllw
07-09-2012, 4:17 PM
So I tried to get this photo in the last post, Photobucket locked up on me. This is my workbench late Sunday night.

http://i1000.photobucket.com/albums/af125/dammitgang/DSCF0024.jpg

It's been a long week !!

joefrank64k
07-09-2012, 4:32 PM
http://i1000.photobucket.com/albums/af125/dammitgang/DSCF0024.jpg

Wow! Quite a week! :)

KalTac
07-09-2012, 6:21 PM
Wow, really nice. Thanks for the post...

Tack425
07-09-2012, 6:57 PM
Nice work. Too bad Im here near San Francisco. Looks like Ill have to tackle this one on my own. So do you start the process with Skyy? or end with it?

frankDmole
07-10-2012, 10:54 AM
Thanks, I have been looking to get a better way of cutting my inserts other than a razor blade.
Parts list and plans printed, off to shopping.

Eddy's Shooting Sports
07-10-2012, 11:07 AM
Hot wire cutting makes for great results as presented here, but it sure is a lot of hassle.

Go to Bed Bath and Beyond with your 20% off coupon you got in the mail and buy an electric carving knife. You know, the one with two reciprocating blades. Lay your gun on the foam, trace it with a sharpie, and carefully make your cuts. Think like you are using a jigsaw in wood and sacrifice the foam being cut out so you are always ending a cut into the sharp corners. Total time for a simple cutout is about ten minutes.

I keep my e-knife in my toolbox at the shop and offer to let any customer buying a pelican style case to use it. It even works well with the pick and pluck foam.


Greg David
Eddy's Shooting Sports
400 Moffett Blvd.,Suite F
Mountain View, CA 94043
(660)969-GUNS

T-F 12-7 W 12-9 Sat 11-5
Closed Sun/Mon

Elwood_Blues
07-14-2012, 6:32 PM
Way better, Thanks.

That is a pretty nice cutting station you built there. I wish I had room for something like that. Are you going to put a spring on it as others suggested to keep tension on the wire?

Nice work. Too bad Im here near San Francisco. Looks like Ill have to tackle this one on my own. So do you start the process with Skyy? or end with it?

Neither, you can start light, with a beer. But about 30 or so minutes into it, you'll need a serious drink. It doesn't have to be Skyy, or even vodka for that matter. It should be a drink of your choice (possibilities are nearly endless here), but you should not skip it, I warned yous :D

Hot wire cutting makes for great results as presented here, but it sure is a lot of hassle.

Go to Bed Bath and Beyond with your 20% off coupon you got in the mail and buy an electric carving knife. You know, the one with two reciprocating blades. Lay your gun on the foam, trace it with a sharpie, and carefully make your cuts. Think like you are using a jigsaw in wood and sacrifice the foam being cut out so you are always ending a cut into the sharp corners. Total time for a simple cutout is about ten minutes.

I keep my e-knife in my toolbox at the shop and offer to let any customer buying a pelican style case to use it. It even works well with the pick and pluck foam.


What he's referring to is a process that is somewhat like in the video below. However, if you have time and want a little project, hotwire is the way to go. Yes, it is a lot of hassle, but the results are incomparable in my opinion between the two.

mXhT7WtIsTg

finyllw
07-14-2012, 9:19 PM
Thanks EB,
I wanted to make one big enough for a certain project, I read what you said about supporting the work, so I made it big (hopefully enough). I really don't have room for it but I'm sure I'll find a place for it.

Well, I blew up my second transformer today. I was going to do all the ohms law stuff to try to figure out why I popped the first one, but once I got everything hooked up again, I got impatient and started cutting. I took it real slow, but the wire kept cooling off and the foam would bundle up on the wire and stop all progress. Then the "Magic Smoke" escaped and I couldn't collect it fast enough to get it back in.

I found a very cool website, did a little reading and found out the answers for my questions. Check this out,

http://hotwirefoamcutterinfo.com/Hot_Wire_Foam_Cutter_Info/__SupplyCalc.html

There are some links, and of course products to buy. It seams that my 20gauge wire needs about 6-8 amps to work properly, so the 2 amp Radio Shack transformer just didn't have enough ooomph to get the job done. So, smaller gauge wire and lots of time, or BIGGER transformer for more power and faster cutting. Since I don't have any patience can you guess which way I am going?

Elwood_Blues
07-15-2012, 10:42 AM
That is weird that you keep frying transformers. If you got them from Radio Shack, I think they'll take them back. It also may be a good idea to put a fuse in the line regardless of how big of a transformer you use.

finyllw
07-15-2012, 5:16 PM
I think the difference is the wire. I think you said you are using 24 gauge wire that has a resistance of about 1.6 ohms. The wire I am using is 20 gauge, it has exactly haly the resistance. It's putting too much of a load on the transformer even after using the dimmer.

I want a HOT wire, so I'll be oredering a BIG transformer on Monday. I think the idea of a fuse is a good one. I'd rather blow a fuse than another transformer.

finyllw
07-17-2012, 3:31 PM
Well today I ordered a bigger transformer. 6 volts but 16 amps. Should be able to cook the foam right out of any hole. I ordered my stuff from Jacobs Online,
http://www.jacobs-online.biz/transformers.htm

I was dealing with Gary Jacobs, asking him all kinds of questions, and he suggested the one I ordered. It's actually a 12v 8 amp or a 6v 16 amp depending on how you wire it up. Gary was very helpful. If you are going to be building a foam cutter I would definitely check out his website. LOTS of really good info there to get you going in the right direction the first time. I should have my transformer Thursday or Friday, I'll be making foam cuts on Saturday if not sooner. I will post pics asap.

Cali-Shooter
07-17-2012, 3:48 PM
Very nice DIY. Nice, clean job.

VenturaMunitions.com
07-18-2012, 7:06 AM
Brilliant results, thanks for sharing this. Great weekend project.

fouber
07-18-2012, 1:58 PM
Very clean. Thanks for sharing

Dark Sky Solutions
07-18-2012, 7:24 PM
Got 2 ft of n-wire in the mail today thanks to footb82!!!

Great calgunner right there!!!!

Szabi B
07-20-2012, 11:52 AM
A+ Job

reloadyour9
07-30-2012, 4:10 PM
Great job on the cutting and the write up OP! Guys, one thing that needs to be mentioned as I did not see it in any of the pages.......be careful with the material you are buying!! I own a foam fabrication shop here in LA and do plenty of case work for Pelican as well as other companies (however mine is cut on a waterjet), and polyurethanes, or ethers, are highly flammable. Make sure you do one of two things, buy only flame retardant material, or do not stop while in the process of hot wiring the foam, or up in smoke it goes. Trust me, I almost burnt down my building several times when one of my automated hot wire tables motor went out while in the process of hot wiring.

Make sure you find out what material companies like Miller are selling you, and if you are unsure, PM me. The reps at Miller dont know much about the material, especially when it comes to the properties ( I supply them, they are just a distributor of my product).

Also, you can test the material by putting a lighter to it. It will burn, but if you remove the flame and it continues to burn, it is not flame retardant, so take extra precautions when hot wiring. If the fire goes out, you've got some good stuff (most likely 2# char ester. Ethers are no bueno, esters are FR.

Again OP, great job! Didn't mean to hijack, just want people to be aware. All it takes is somebody to interrupt while wiring, and the garage is toast.

Here is one I did, but using polyethylene, which is a closed cell material (water resistant)

http://i252.photobucket.com/albums/hh9/reloadyour9/2ca9089d.jpg

http://i252.photobucket.com/albums/hh9/reloadyour9/da635225.jpg

http://i252.photobucket.com/albums/hh9/reloadyour9/7b2ca4a8.jpg

finyllw
07-31-2012, 10:48 AM
Thanks for the info "reloadyour9"

Ok fellas, update as promised.

I finally had time to get everything put together, I used a 6v 16A transformer, with a dimmer. I can get the wire red hot to melt off residual foam, then turn the heat down to cut. NO TRANSFORMER MELTDOWNS YET !! :)

I used the first aid kit steel (sealed) box, cut out the metal divider then cut the foam. I used 3 layers, 1/2" thick on the bottom, and top, and 3/4" in the middle. It all went relatively easy, had all the foam cut in less than an hour. I'm very happy with the results. The most important thing is PATIENCE !! Take your time with every step, trace your outline carefully, with the pen or pencil slightly tilted in so the foam will hold your ??? snugly in place. When cutting a straight line, I used a yardstick clamped to the frame. I was able to trim 1/8" using that method.

http://i1000.photobucket.com/albums/af125/dammitgang/DSCF0007.jpg
http://i1000.photobucket.com/albums/af125/dammitgang/DSCF0049.jpg
http://i1000.photobucket.com/albums/af125/dammitgang/DSCF0054.jpg

Outsiders
08-22-2012, 9:54 PM
thanks for posting this!! I finished buildin mine and already cut a few and came out clean! Anybody in San Diego wants to have theirs cut, holla!

finyllw
08-23-2012, 8:48 AM
"Outsiders" Thanks for the reminder,

Folks, I built this project mostly out of curiosity, and I did want to complete a couple of guncase projects. Somebody mentioned early on that it would be nice if someone would cut foam for them.

Well if you make a good template, and supply the foam, and if you trust me, I will cut the foam for you, or you can use my setup to cut your foam. I'm in NW OC, pm me and we'll see if we can work out the timing.

P.Charm
08-23-2012, 9:41 PM
outsiders cuts
http://img.photobucket.com/albums/v447/icxprince/2012-08-11141102-1.jpg

ElDub1950
08-29-2012, 1:19 PM
another source of the Nichrome wire .. but this looks like a lifetime supply for $18
http://www.amazon.com/Nickel-Chromium-Resistance-Bright-Diameter/dp/B000FMUF4E/ref=pd_cp_hi_3

ElDub1950
08-29-2012, 1:25 PM
has anyone tried putting their pistol on a xerox machine to make a correct 1:1 profile pic?

Seems like the easy way to make a template to transfer to a piece of cardboard. Not sure if it will make the copy in exact size.

I don't have a xerox machine and somehow my local Copy Shop freaks out when I walk in and pull out my guns.:p

finyllw
08-29-2012, 1:32 PM
The shadows that might come from the copy machine could throw you off. I'll try it later today and let you know.

Elwood_Blues
08-30-2012, 3:46 PM
Nice cuts everyone! I'm glad to see that I inspired so many of you. Here is my latest little project I did for someone free of charge. I had scrap pieces of foam, one of which I had to cut on every side to make it fit :D Idea as suggested by 'finyllw'

http://i31.photobucket.com/albums/c382/mustangphil302/Foam%20Cutting/DSC_0939.jpg
http://i31.photobucket.com/albums/c382/mustangphil302/Foam%20Cutting/DSC_0941.jpg

KalTac
08-31-2012, 12:15 AM
Flipping NICE !!! outsiders cuts
http://img.photobucket.com/albums/v447/icxprince/2012-08-11141102-1.jpg

P.Charm
08-31-2012, 10:54 AM
Flipping NICE !!!

Thanks. It was Ousiders and my first one. with his setup, it worked like a charm.

Outsiders
08-31-2012, 6:00 PM
Thanks. It was Ousiders and my first one. with his setup, it worked like a charm.

i'll post pics of my setup as soon as i find my cam

Bunsen
08-31-2012, 6:07 PM
Looks like I have a weekend project to plan out.

Outsiders
08-31-2012, 6:18 PM
here's my set up.

http://i77.photobucket.com/albums/j71/icxbrian/IMG_1823.jpg
http://i77.photobucket.com/albums/j71/icxbrian/IMG_1825.jpg

Elwood_Blues
08-31-2012, 7:03 PM
here's my set up.

http://i77.photobucket.com/albums/j71/icxbrian/IMG_1823.jpg
http://i77.photobucket.com/albums/j71/icxbrian/IMG_1825.jpg


That is awesome! Do you mind posting a picture of your cutter?

P.Charm
08-31-2012, 9:02 PM
here's my set up.

http://i77.photobucket.com/albums/j71/icxbrian/IMG_1823.jpg
http://i77.photobucket.com/albums/j71/icxbrian/IMG_1825.jpg

did you keep my template. I think i want to do mine like yours.

finyllw
09-01-2012, 7:03 AM
Outsiders,

That is a way cool set up, uh, the case and the guns.

It would be cool to have a way to borrow templates. I have a stock 1911 template if anybody wants to borrow it. I'll be working on a M4 flat top template soon. I'm going to make it without anything on top, buttstock fully collapsed then make add on templates for scopes etc.

Outsiders
09-01-2012, 8:59 AM
here's my cutter... used some scrap wood laying around and a platic sheet on top for a smooth top for the foam to glide. i also used a turnbuckle for tension. u could get it tighter than using a spring.

http://i77.photobucket.com/albums/j71/icxbrian/Untitled.jpg

Tackman11
09-01-2012, 9:10 AM
Well done

KalTac
09-01-2012, 11:42 AM
That would be great!
i'll post pics of my setup as soon as i find my cam

KalTac
09-01-2012, 11:45 AM
Way cool

here's my cutter... used some scrap wood laying around and a platic sheet on top for a smooth top for the foam to glide. i also used a turnbuckle for tension. u could get it tighter than using a spring.

http://i77.photobucket.com/albums/j71/icxbrian/Untitled.jpg

atc4usmc
09-01-2012, 9:28 PM
Tagged! Outsiders, PM coming your way soon Chief! ;)

Elwood_Blues
09-03-2012, 9:42 AM
I wish i had room for setup like Outsiders'. Might have to rearrange the garage a bit :DI love the turnbuckle idea.

atc4usmc
09-03-2012, 9:07 PM
finyllw, can you scan and email your template for the 1911?

Anyone else have templates for pistols, 1911, H&K, S&W etc..?
Templates for AR's would be great too but Im not sure if we could devise away to scan them so we could distribute electronically..

echoarms
09-04-2012, 1:54 PM
God I wish I had few enough guns to make this viable.

finyllw
09-05-2012, 10:34 AM
atc4usmc,

I will try to get a 1911 and mag template copied and sent out ASAP.

echoarms,

In a previous post I offered my cutter for all to use. Contact me if you want/need to cut some foam.

P.Charm
09-05-2012, 6:52 PM
God I wish I had few enough guns to make this viable.my pelican only has one.

5150bronco
09-06-2012, 1:08 AM
Great write up. Thanks.

Has anybody thought of using proton foam cutter or hot knife?

I am looking to start making stuff now. Thanks.

supersonic
09-17-2012, 11:21 AM
PM sent. I have a brand new / never used Proxxon Table for sale in the Marketplace for $75 (IIRC).

-SS

shortyforty
09-21-2012, 11:35 PM
Awesome job! I always wondered how this was done. Thanks for posting.

Dan FS71
09-24-2012, 10:59 AM
Excellant.

budah1999
11-20-2012, 2:46 AM
this process is called hot wire cutting they use it alot in homebuilt aircraft but becareful when selecting your foam not all can be cut with this method.you can purchase most of the items for buliding the cutter at AIRCRAFT SPRUCE in Chino CA i think they sell foam too i would check your local upholstry shops. good job on the case bro!

Big bug
11-21-2012, 7:56 PM
I applaud you sir. Very neighborly...
God Bless

atc4usmc,

I will try to get a 1911 and mag template copied and sent out ASAP.

echoarms,

In a previous post I offered my cutter for all to use. Contact me if you want/need to cut some foam.

patriot_man
11-22-2012, 10:57 AM
Will this also work for closed cell foam? Anyone know?

Cary1911
11-25-2012, 7:32 PM
this thread is awesome. i have been wondering where to buy foam for my rifle case, and how to build a foam cutte, and this thread delivered. thanks!

Quinc
11-28-2012, 1:15 PM
Great job on the cutting and the write up OP! Guys, one thing that needs to be mentioned as I did not see it in any of the pages.......be careful with the material you are buying!! I own a foam fabrication shop here in LA and do plenty of case work for Pelican as well as other companies (however mine is cut on a waterjet), and polyurethanes, or ethers, are highly flammable. Make sure you do one of two things, buy only flame retardant material, or do not stop while in the process of hot wiring the foam, or up in smoke it goes. Trust me, I almost burnt down my building several times when one of my automated hot wire tables motor went out while in the process of hot wiring.

Make sure you find out what material companies like Miller are selling you, and if you are unsure, PM me. The reps at Miller dont know much about the material, especially when it comes to the properties ( I supply them, they are just a distributor of my product).

Also, you can test the material by putting a lighter to it. It will burn, but if you remove the flame and it continues to burn, it is not flame retardant, so take extra precautions when hot wiring. If the fire goes out, you've got some good stuff (most likely 2# char ester. Ethers are no bueno, esters are FR.

Again OP, great job! Didn't mean to hijack, just want people to be aware. All it takes is somebody to interrupt while wiring, and the garage is toast.

Here is one I did, but using polyethylene, which is a closed cell material (water resistant)




So group buy? :D

Cary1911
11-28-2012, 2:10 PM
here's my set up.

http://i77.photobucket.com/albums/j71/icxbrian/IMG_1823.jpg
http://i77.photobucket.com/albums/j71/icxbrian/IMG_1825.jpg

this is awesome. exactly what i want to do for mine, similar firearms and all.

atc4usmc
12-02-2012, 9:01 PM
Anyone tried this with pick n pluck? I have a case laying around with pick n pluck that I would like to use. If not, I guess Ill have to replace the foam.

ChuckD
12-04-2012, 12:32 PM
Does it have to be "Nichromium" wire? Would 24ga copper wire work? Just wondering 'cause I have tons of that.

Dark Sky Solutions
12-04-2012, 1:22 PM
Does it have to be "Nichromium" wire? Would 24ga copper wire work? Just wondering 'cause I have tons of that.

I tried copper wire on my rig and couldn't get the heat out of it. Used the nichro wire and worked like a charm


Sent from my IPad so... Ease off the spelling

P.Charm
12-04-2012, 2:04 PM
Does it have to be "Nichromium" wire? Would 24ga copper wire work? Just wondering 'cause I have tons of that.

nicromium has resistance. the 24ga wire doesn't, well not enough to heat up. it will just short out the power supply and shut it down or catch fire and or explode.

Kingofthehill
12-09-2012, 2:26 AM
I cut EPP foam for RC airplanes and if someone wants an easier way, there is 1 mod to your setup if you don't mind.

Instead of the Transformer you can use an Automotive battery charger and still adjust the amperage with a home/wall/light dimmer switch/knob. As for the wire, head to the local guitar/music shop or even fishing leader wire and buy some and play around with what works best on your foam/amperage setup.. I don't even remember what i settled on finally on my foam cutter since i have it dialed in so well i never bust the wire and bought something like 20 feet of it when i first started out.

You did a great job BTW... Very well done.

JOe

Greerdom
12-10-2012, 2:36 PM
thanks for posting this!! I finished buildin mine and already cut a few and came out clean! Anybody in San Diego wants to have theirs cut, holla!

I would LOVE to take you up on this offer. Just purchased a Colt 6920 and a Pelican 1700. PM sent. Thanks to the OP, and all of CGN for sharing your wealth of knowledge.

atc4usmc
12-10-2012, 7:39 PM
Greedom, I believe he transferred out of CA. He's in the Navy!

Greerdom
12-11-2012, 5:39 PM
True story, he moved cross country. Thank you for the "heads up". Fortunately, another Calgunner kindly offered the use of their cutter. LOVE this damn place! Thanks again for the hospitality.

atc4usmc
12-11-2012, 10:15 PM
Oh really...ask said cal gunner if I can get in on the action!

And yes, this place is great!

Dark Sky Solutions
12-12-2012, 5:59 PM
Well I got tired of fumbling with my homemade setup. I broke down and am waiting for my proxxom hot wire cutter to come in the mail!!!! Can't wait


Sent from my IPad so... Ease off the spelling

Elwood_Blues
12-12-2012, 8:58 PM
^ Cheater :hide: :D

Dark Sky Solutions
12-12-2012, 10:04 PM
^ Cheater :hide: :D

Yeah I know. I have been messing with new wire and can't get the voltage right from my tattoo gun power supply so instead of trying more ingot abgreatbdeal on one and did it.

I cheated,


Sent from my IPad so... Ease off the spelling

Outsiders
12-13-2012, 4:08 PM
True story, he moved cross country. Thank you for the "heads up". Fortunately, another Calgunner kindly offered the use of their cutter. LOVE this damn place! Thanks again for the hospitality.

Yea sorry guys! Send ur stuff here and i'll cut it! Im in Florida now! LOL! .... YESE! hicap mags and no bullet button!!! As much as i hated the cali gun laws, I still rather be there in cali... WESTSIDE FO' LIFE. HAH!

Greerdom
12-20-2012, 9:29 PM
I couldn't be happier with the way mine turned out. A million thanks again to the CGN community and the OP.
http://i1274.photobucket.com/albums/y423/Jason_Greer/IMG_1086_zpse35db67a.jpg

atc4usmc
12-21-2012, 2:30 AM
That looks great! Nicely done.

s*******n
12-21-2012, 6:18 PM
Is there a Calgunner in the SF Bay Area who has a foam cutter and can help me? THANKS!

EssDee
12-22-2012, 8:40 AM
Sweeeeett!!!!!!

Bonecrusher
12-22-2012, 11:13 PM
I friggin love the Clean, Organized looks of a quality foam set-up. Excellent write up. Done right, it makes you feel a bit more professional, as in 007ish!:auto:

Greerdom
12-23-2012, 11:05 AM
That looks great! Nicely done.

Sweeeeett!!!!!!


Thanks boys! Feeling very 007ish sums it pretty darn well.

Letterman52
01-07-2013, 7:00 AM
Anybody willing to help me out with this in the Temecula area. I have to Pelican 1720's I'm looking to do.

Dark Sky Solutions
01-07-2013, 7:06 AM
Nice triple post brother.

I am in SD and am waiting on my new cutter to arrive still. I will keep you posted.



Anybody willing to help me out with this in the Temecula area? I have two Pelican 1720's I'm looking to do.

Letterman52
01-07-2013, 7:23 AM
Fixed. Yeah the internet isn't all that great at work. Anyways thanks. Please let me know.

finyllw
01-07-2013, 8:42 AM
Letterman52

I'm in Yorna Linda if you want to make the drive. You can work at my place or borrow mine if you would like.

Dark Sky Solutions
01-08-2013, 11:25 AM
Just got my new Proxxon cutter last night!!!!!

Anyone know where I can get some good foam in SD area?

Letterman52
01-08-2013, 11:44 AM
I should be getting my cases this weekend. I'll PM you if I do.

Elwood_Blues
01-08-2013, 11:15 PM
Just got my new Proxxon cutter last night!!!!!

Anyone know where I can get some good foam in SD area?

Here:
http://www.caseman.com/category/Foam-Replacements.html

I think Nalpak in El Cajon has them too...
http://www.nalpak.com/

EDIT: oh yeah, and this guy:
http://www.ebay.com/sch/werica2012/m.html?item=271128814426&pt=LH_DefaultDomain_0&hash=item3f2089635a&rt=nc&_trksid=p2047675.l2562

P.Charm
01-09-2013, 12:07 PM
Just got my new Proxxon cutter last night!!!!!

Anyone know where I can get some good foam in SD area?

cheaper to buy online. I forgot where I got mine but it came out to 20bucks shipped for a top (egg crate) and bottom.

atc4usmc
01-09-2013, 10:32 PM
Anyone tried cutting the pick-n-pluck foam with a cutter? I have a 1450 that I am looking to cut for pistols but it has the P&P foam. Should I sell/scrap that and get non-P&P or closed cell?

P.Charm
01-11-2013, 7:29 AM
Anyone tried cutting the pick-n-pluck foam with a cutter? I have a 1450 that I am looking to cut for pistols but it has the P&P foam. Should I sell/scrap that and get non-P&P or closed cell?

scrap the pick and pull.

rkt88edmo
01-11-2013, 7:44 AM
I would definitely sell the pick and pluck if you are going to cut your own. PnP works great for pistols though.

P.Charm
01-11-2013, 8:02 AM
I would definitely sell the pick and pluck if you are going to cut your own. PnP works great for pistols though.

if you are going to go through the trouble of using a hotwire for a rifle why not use it for a pistol? I just don't like the pick and pull at all. doesn't look good.

Dark Sky Solutions
01-11-2013, 1:32 PM
Anyone have a good inline site for foam?


Sent from my IPad so... Ease off the spelling

us3
01-11-2013, 6:17 PM
Anyone have a good inline site for foam?


Sent from my IPad so... Ease off the spelling

Hello

For local raw foam:

http://www.keystonbros.com/


For local 2' x 3' sheets of Pelican pick and pluck foam:

http://www.caseman.com/


Dealt with both, both great companies.

Thanks

Matt

Bobio
01-11-2013, 6:54 PM
Nice job. When I cut foam I'm like Jack the Ripper.

Elwood_Blues
01-12-2013, 9:35 AM
Jo-Ann Fabric and Craft will have 50% off high density foam by-the-yard on February 1st and 2nd, that's Fri, Sat. They have 1/2"-5" thick. Sale $5.49-$37.49 per yard. The only catch is, it's seafoam green :(

Kinda like this:
http://www.joann.com/images/11/17/8/xprd11178084_m.jpg

Jack Dupp
01-21-2013, 4:46 PM
Anyone in the San Diego area wanna get together and work on this? I picked up a Pelican 3100 and was looking to get some cutouts done as soon as my Sig gets outta jail.

Dark Sky Solutions
01-21-2013, 8:02 PM
Possibly. I got my new hot wire cutter in(yes I cheated). I have a few guys here in SD who all ready have asked to use it. Busy schedule so I haven't been able to help anyone out yet.

Also as a side note. I just started carrying SKB cases. If you know of one you want let me know. Thinking of a GB for 1-3 different size cases in e future.


Sent from my IPad so... Ease off the spelling

SoftwareDrone
01-22-2013, 12:27 PM
Since you've already invested in building the equipment and have some experience now, consider doing a few freebies for Calgunners to get some feedback, then maybe charge for the service for a moderate/reasonable fee.

You beat me to it!
Please let me know if you decide to do this.

kingsfan8888
01-24-2013, 7:39 PM
I've got 3 I need to do I am down.

P.Charm
01-25-2013, 7:17 AM
just build one, outsiders and myself built one unfortunately, i believe he took it with him out of state. it's not hard to do.

marbro
03-30-2013, 8:12 AM
Thanks for the tips

wpage
03-31-2013, 4:13 PM
Good to know!!!

Blueapplepooh
04-01-2013, 10:43 AM
That is a clean set up. Great job.

Alpha Male
04-05-2013, 8:37 AM
Very clean man- I love the humbleness when this came out nice. I'd probably overcut it in trying to be a perfectionist.

Darryl Licht
04-08-2013, 10:16 AM
I love this thread... some very sweet custom cases.

77bawls
04-09-2013, 5:03 PM
Does it have to be "Nichromium" wire? Would 24ga copper wire work? Just wondering 'cause I have tons of that.

I've heard guitar string's work.

ohhh s.k
04-29-2013, 8:16 PM
any cal gunners in south OC willing to help me cut mine?

Nirrad
04-30-2013, 12:24 PM
any cal gunners in south OC willing to help me cut mine?

PM inbound!

jglabe
05-04-2013, 3:19 PM
Tagged

TanMan
05-13-2013, 10:08 AM
I've heard guitar string's work.

It might but you need the thinnest one. The issue is having them not snap on you from the heat and tension.

You need quite a bit of spring tension on the end of the string as they expand when heated. Otherwise they will become slack when you run the current through them. Too much tension and they will just snap.

I tried using thin copper wires and they heat up real quick, but gets too hot and just snap. Power source is another issue. You need to regulate the power but have enough juice to not let the wire cool off too much while cutting.

daltores
05-20-2013, 6:09 PM
now something else i have to do to feed my "do it myself" O.C.D. lol.. very cool

deviljon
05-22-2013, 7:50 AM
May I ask where to purchase just the middle foam pre-cut to fit a Pelican 1750?

kkp
05-22-2013, 2:33 PM
May I ask where to purchase just the middle foam pre-cut to fit a Pelican 1750?

Google is your friend:

Here are two sources:

http://www.pelicancasefoam.com/

http://www.pelican-case.com/replacement-foam.html

Others here:

http://lmgtfy.com/?q=pelican+case+foam

deviljon
05-22-2013, 3:03 PM
Google is your friend:

Here are two sources:

http://www.pelicancasefoam.com/

http://www.pelican-case.com/replacement-foam.html

Others here:

http://lmgtfy.com/?q=pelican+case+foam

Thanks, but the links you provided aren't what I asked for. Looking for something to replace the middle foam only, not complete sets. Also looking for ones pre-cut for the 1750, which those aren't.

I have 2 Pelican 1750's coming in and want to cut different center foams so I can switch it up depending on the type of shooting I plan on doing.

Elwood_Blues
05-25-2013, 10:56 PM
I have not found anyone that sells single sheet. The only way I was able to get those, was through the market place and it was about 20 bucks. The best deal for the set that I found is here:
http://www.ebay.com/itm/Pelican-1750-1751-replacement-foam-Foam-for-the-Pelican-1750-3-Pieces-/281106982608?pt=LH_DefaultDomain_0&hash=item41734826d0

mrwilson99
06-01-2013, 11:32 AM
I have a case, would love to get some help with cutting the foam in the LA/SGV area! Will pay of course :)

P.Charm
06-04-2013, 9:51 AM
here is where outsiders and I bought ours from
http://www.foambymail.com/charcoal-foam.html

Nirrad
06-04-2013, 9:58 AM
here is where outsiders and I bought ours from
http://www.foambymail.com/charcoal-foam.html

That's where I got mine too. Good product, reasonably priced.

Cheeseball
06-12-2013, 9:26 PM
So I was looking for new " ears " for the range online and found these on Amazon,,

http://imageshack.us/a/img248/9002/earsd.th.jpg (http://imageshack.us/photo/my-images/248/earsd.jpg/)

As I was well on my way to finishing the weekends left over beers I bought a case for them as well - www.seahorse.net on Amazon because Amazon said " most people also purchased ",,,I was like,,hey I'm most people:smartass: The good part of the case was the foam inserts,,the main piece is called " pick and pluck " foam,,,9 cubes is a square inch

http://imageshack.us/a/img801/6174/foam2.th.jpg (http://imageshack.us/photo/my-images/801/foam2.jpg/)

http://imageshack.us/a/img850/9858/foam3.th.jpg (http://imageshack.us/photo/my-images/850/foam3.jpg/)

http://imageshack.us/a/img5/3141/foam1f.th.jpg (http://imageshack.us/photo/my-images/5/foam1f.jpg/)



I researched online a place that you can order custom foam any size you want of all 3 main types of foam for a case,,,,

http://www.caseclub.com/order-foam.htm

good luck and let me know what you think,,,,

cheese

joechoi107
06-19-2013, 6:08 PM
Finally got around to doing this. Hotwire foam cutters are so freaking awesome.

http://i872.photobucket.com/albums/ab283/joechoi107/photo1_zps77a8a3c4.jpg (http://s872.photobucket.com/user/joechoi107/media/photo1_zps77a8a3c4.jpg.html)

http://i872.photobucket.com/albums/ab283/joechoi107/photo2_zps9d342220.jpg (http://s872.photobucket.com/user/joechoi107/media/photo2_zps9d342220.jpg.html)

http://i872.photobucket.com/albums/ab283/joechoi107/photo3_zpse405a150.jpg (http://s872.photobucket.com/user/joechoi107/media/photo3_zpse405a150.jpg.html)

Elwood_Blues
06-20-2013, 6:18 AM
Finally got around to doing this. Hotwire foam cutters are so freaking awesome.
Hell yeah they are! Nice results

evilbisquit
08-01-2013, 4:37 PM
Finally got around to doing this. Hotwire foam cutters are so freaking awesome.

Wow, that set up is clean. Nice looking kit, my man.

muritku
08-27-2013, 3:35 PM
Any Calgunner from Ventura County or San Fernando Valley have a setup and can help a fellow member out?

Please let me know I can pay for the service.

thanks!

kkp
09-17-2013, 11:30 PM
Sweet. :) And I'm jealous of you KAC FF RAS!

NorCalAthlete
10-06-2013, 8:26 PM
I'm amazed nobody's said it yet, but for those looking for singular middle pieces to cut - why not just buy the 3 pack anyway and cut each one differently? I'd imagine you all have safes that the guns sit in most of the time anyway - why not cut 3 different middles for when you want to hit the range? 1 case, 3 different configurations.

Version 1: Rifle / Pistol
Cut for 1x AR + 1x Sidearm + X amount of mags for each

Version 2: Rifle / Rifle
Cut for 2x ARs + mags + accessories

Version 3: _________? (hunting perhaps?)
Cut for 1x AR lower + 2x AR uppers (18" w/ scope, 14.5" w/ red dot? .22lr upper + 5.56 upper? 5.56 + 7.62x39?) + sidearm + extra mags.

Version 4: Pistol / Pistol / Pistol
Cut for 1x AR pistol + 2-3x other pistols.

I dunno just a thought.

Darryl Licht
11-18-2013, 11:20 AM
Anybody with one of these cutters in the IE/OC area willing to help me when I get my Pelican Case?

socal147
12-08-2013, 2:08 PM
I am in Apple Valley. If you need your foam cut, and want to use my cutter, pm me. I just got done testing it........

Patrick

finyllw
02-20-2014, 9:51 AM
Hey all,

I will be moving to Co pretty soon. I will be needing to get rid of my cutter. It has a fairly large base of smooth wood, and a pretty powerfull power supply. It needs to be modified a little bit to position the new power supply, it is way bigger than the original one which burned out. It wouldn't take much to make it nice, I just don't have the time. I can't post pictures right now as I am 1200 miles away from it, but if you are interested, let me know and I can send pictures when I get home. I'm thinkin $50 ought to cover it. I probably have $80 into it.

DDM4
02-20-2014, 10:05 AM
Hey all,

I will be moving to Co pretty soon. I will be needing to get rid of my cutter. It has a fairly large base of smooth wood, and a pretty powerfull power supply. It needs to be modified a little bit to position the new power supply, it is way bigger than the original one which burned out. It wouldn't take much to make it nice, I just don't have the time. I can't post pictures right now as I am 1200 miles away from it, but if you are interested, let me know and I can send pictures when I get home. I'm thinkin $50 ought to cover it. I probably have $80 into it.

I will take it. I live in Anaheim. Can we schedule a meet? I am going to be out of town next week. Sounds like you are out of town right now.
We can do it when i return if you want.

finyllw
02-20-2014, 10:15 AM
DDM4,

Message sent

DDM4
02-20-2014, 11:10 AM
Replied.
Thanks!

NorCalAthlete
04-08-2015, 7:00 PM
Anyone in Nor Cal / bay area have a hotwire set up? I have some pieces I'd like to do right this time around. Used a throwing knife last time with decent results but not as clean as I'd like.

firepower308
06-13-2015, 6:00 PM
Awesome write up. Thanks :)

DDM4
06-25-2015, 9:25 PM
Bought a hot wire setup from finyllw in February 2014 and have not used it. For sale to the first local pick up for $60.00. Located in Anaheim.

gobler
07-20-2015, 8:00 AM
Bought a hot wire setup from finyllw in February 2014 and have not used it. For sale to the first local pick up for $60.00. Located in Anaheim.

would happen to still have it and maybe a photo?

DDM4
07-20-2015, 5:44 PM
I do still have it but I don't have a photo right now. It is homemade but the table setup that he made for it is very nice. I'm having construction work done on my house right now and my garage is a mess. I will try to take some pictures when I can find it and PM you.
P.s. I also have a pelican case and new foam that I might let go of as well.