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  #41  
Old 06-22-2012, 11:57 PM
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Awesome! Should be a sticky.
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  #42  
Old 06-23-2012, 11:13 PM
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tag
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  #43  
Old 06-24-2012, 4:26 AM
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Quote:
Originally Posted by voiceofreason View Post
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.
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  #44  
Old 06-24-2012, 8:08 AM
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Quote:
Originally Posted by Elwood_Blues View Post
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
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  #45  
Old 06-24-2012, 3:23 PM
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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!



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  #46  
Old 06-24-2012, 5:05 PM
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Quote:
Originally Posted by wchutt View Post
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!

Clever method of maintaining tension on the wire! Good stuff!
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  #47  
Old 06-24-2012, 6:08 PM
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Quote:
Originally Posted by joefrank64k View Post
Clever method of maintaining tension on the wire! Good stuff!
+1. I like the way you used the spring.
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  #48  
Old 06-25-2012, 9:47 AM
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Quote:
Originally Posted by jmlivingston View Post
This is pretty good stuff, I've moved it over to the "CGN Best Of" section.

John
Thanks!

Quote:
Originally Posted by wchutt View Post
Thank you for help on trouble shooting when I did this. I skipped step one in the second post... never again!
Told ya

Quote:
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.

Quote:
Originally Posted by joefrank64k View Post
Clever method of maintaining tension on the wire! Good stuff!
Quote:
Originally Posted by Casual_Shooter View Post
+1. I like the way you used the spring.
Exactly right.
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Weapons Case Hotwire Foam Cutting

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  #49  
Old 06-25-2012, 11:18 AM
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Dammit, back to the hardware store. Thanks for the spring idea.
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  #50  
Old 06-25-2012, 11:30 AM
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Here's the first project I will be practicing on.

http://i1000.photobucket.com/albums/...g/DSCF0007.jpg

http://i1000.photobucket.com/albums/...g/DSCF0008.jpg
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  #51  
Old 06-25-2012, 2:23 PM
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I like the First Aid Kit idea, that's awesome. It should be pretty easy. Post results, chop chop
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  #52  
Old 06-25-2012, 2:36 PM
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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.
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  #53  
Old 06-25-2012, 2:48 PM
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damn those are some clean cuts, very nice!
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  #54  
Old 06-26-2012, 8:09 PM
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Wow very nice.. Thanks for the write up. Will be building one and putting it to use soon.
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  #55  
Old 06-30-2012, 8:09 AM
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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.
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  #56  
Old 07-01-2012, 9:05 AM
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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.









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.
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  #57  
Old 07-01-2012, 1:18 PM
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Well I couldn't wait so I found some scrap foam and made a smaller case for a couple pistols



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  #58  
Old 07-01-2012, 6:14 PM
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Quote:
Originally Posted by DocCrazyJ View Post
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

Here is where I got my nichrome wire, it came fast;
http://www.ebay.com/itm/12-feet-24-g...#ht_606wt_1185

Quote:
Originally Posted by DocCrazyJ View Post
Well I couldn't wait so I found some scrap foam and made a smaller case for a couple pistols



Looks good!
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  #59  
Old 07-01-2012, 10:16 PM
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great tips in this thread.

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

http://snipershide.com/forum/ubbthre...75#Post2961775
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  #60  
Old 07-02-2012, 8:50 AM
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Great work!
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  #61  
Old 07-04-2012, 1:50 PM
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What case is that? And what kind of foam?
Awesome job!
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  #62  
Old 07-04-2012, 2:54 PM
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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.
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  #63  
Old 07-04-2012, 3:24 PM
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Quote:
Originally Posted by mtsul View Post
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


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



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



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.
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  #64  
Old 07-04-2012, 9:01 PM
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Quote:
Originally Posted by mtsul View Post
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!

Quote:
Originally Posted by sarabellum View Post
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.
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  #65  
Old 07-06-2012, 10:03 AM
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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?
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  #66  
Old 07-06-2012, 11:41 AM
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Do you think the wire out of an old toaster would work?
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  #67  
Old 07-06-2012, 3:30 PM
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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.
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  #68  
Old 07-07-2012, 8:26 AM
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Quote:
Originally Posted by Quinc View Post
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-g...item3a76ab9674
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  #69  
Old 07-09-2012, 1:37 PM
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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.
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  #70  
Old 07-09-2012, 3:29 PM
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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/...g/DSCF0016.jpg
http://i1000.photobucket.com/albums/...g/DSCF0018.jpg
http://i1000.photobucket.com/albums/...g/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!!
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Old 07-09-2012, 3:37 PM
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Quote:
Originally Posted by finyllw View Post
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.





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!
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Old 07-09-2012, 3:46 PM
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Way better, Thanks.
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Old 07-09-2012, 4:17 PM
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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/...g/DSCF0024.jpg

It's been a long week !!
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Old 07-09-2012, 4:32 PM
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Wow! Quite a week!
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  #75  
Old 07-09-2012, 6:21 PM
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Wow, really nice. Thanks for the post...
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Old 07-09-2012, 6:57 PM
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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?
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  #77  
Old 07-10-2012, 10:54 AM
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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.
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  #78  
Old 07-10-2012, 11:07 AM
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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
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Greg David
Eddy's Shooting Sports
(650)969-GUNS

400 Moffett Blvd., Suite F
Mountain View, CA 94043

www.eddysguns.com

Tue-Fri 12-7, Sat 11-5
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  #79  
Old 07-14-2012, 6:32 PM
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Originally Posted by finyllw View Post
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?

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Originally Posted by Tack425 View Post
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

Quote:
Originally Posted by Eddy's Shooting Sports View Post
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.

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Old 07-14-2012, 9:19 PM
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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...upplyCalc.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?
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