PRECISE StormCase Foam-Cutting

[supersonic]

I've searched for different methods of cutting the dense foam in Hardigg Storm Cases, as I am getting one for a precision shooter very soon. I was fortunate to come upon a "scrap" piece from an actual S.C. to "practice" on. I used 2 methods I found somewhere on these threads: using an electric ("turkey") carving knife; and a 3.5" straight razor. Both left the results "less than satisfying" (i.e. cut-out "walls" not consistent/straight-down cuts; cuts left "layers" of different shapes/sizes that were like "thin flaps" that could be peeled out by hand) results. Sorry for the length, I just tried to be descriptive as possible. Any help??? anyone???? I'll pay?!
S.S.

[Budd]

Hot-wire.

[5968]

+1 on the hotwire.

[Nefarious]

heres what your looking for

http://www.calguns.net/calgunforum/showthread.php?t=56906

[shark92651]

Something like this would be a cool project and give you excellent results, although it doesn't have to be this elaborate:

http://www.hhhh.org/~joeboy/resources/hotwire_foam_cutter/hotwire_foam_cutter.html

[Jicko]

Search: "cut foam"

Here it is!

http://www.calguns.net/calgunforum/showthread.php?t=58461

[sintax]

I took a super thin fish filleting knife and got it super hot on the stove and then used that to cut.

I'm thinking it took maybe 2-4 yrs off of my life inhaling those fumes from the burning foam, but it came out "alright". It does not look pro, but does not look like a 4 yr old did it either. I'm happy enough with it.

[Grakken]

Cutting

I have a stormcase and I just used a brand new exacto blade.
I bought some posterboard, outlined my rifle with a sharpie, cut the posterboard to get my rifle outline only, placed on foam and started to cut.

It's not PERFECT but it doesnt look janky either.. It did take me forever to complete though.

[Sgt Raven]

I haven't tried it, but read about others who froze the foam before cutting it.

[damon1272]

Freeze the foam and use an electric carving knife. It works good.

[uzigalil]

http://www.demandproducts.com/index.html

[Mute]

Hot knives work quite well, but if you don't want to spend that much and you have the patience, an electric knife works. Just mark the foam with a Sharpie on the downward facing side and follow the lines. That's what I usually do. Here's one of those results:



The electric knife works best if you cut all the way through the foam. If you plan to make cuts that don't go all the way through, you'd probably get better results with either a hot knife or wire.

[Prc329]

I've said it once and I'll say it 1000 times. That is one beautiful rifle.

[supersonic]

I've checked out everythingyou guys have shown me (thank you, by the way!), and have tried everything (except for building a hot wire table-I'm only doing this once in the foreseeable future), but I'm still not happy with anything short of the "near-perfect" wall cuts- which I didn't come close to. What I'm getting at is this: IS there anyone of you guys w/ hot wire-type device (or one that will produce the results I'm looking for) that would be willing to do this for me ( I will, of course, pay you & provide foam)????? Nor-Kal preferred (for convenience), but not mandatory. Just looking for the "best man (or woman) for the job!!!!!! Thanks.
S.S.

[rksimple]

I did mine with a normal kitchen knife. I heated it up over the stove till it was super-hot, then did a little cutting till it cooled. Turned out pretty nice. I'll see if I can get a pic when I get home.