Tool control foam cutting

[Bigplum]

Hi folks ,
What's the best way to cut out tool control foam,
( I need to do a lot of tool boxes for work)
I know it can be done the hard way with a scalpel and some firms offer a laser cutting service ( but too much money to get pass the boss)

I once saw a tool for the job but cannot find it or even the website now,
Some people say using a Dremel with a tile grouting bit works well
Any suggestions ?

 

[Ruger_556]

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[jetmechabq]

I cut a lot of foam!!!!! I spent 24 ears on AD USAF so I know foam. take chalk and sharpen it like a pencil then trace your tools in the place you want them. go to harbor freight and buy a hot knife and extra blades and have fun. I would use some scrap foam to practice on with the hot knife.

 

[bahcoswed]

Think think and think again how the organisation should be! Then draw of your tools and cut with a carpet knife! http://www.garagejournal.com/forum/showthread.php?t=202990&highlight=show+homemade+foam

 

[Caddis295]

I cut a lot of foam!!!!! I spent 24 ears on AD USAF so I know foam. take chalk and sharpen it like a pencil then trace your tools in the place you want them. go to harbor freight and buy a hot knife and extra blades and have fun. I would use some scrap foam to practice on with the hot knife.

I have to agree with this method. This the easiest method of making it all work. Plus....it allows you manipulate the depth. I was Army aviation, had to do this all the time for accountability. You can also, trace tools and use a soldering iron to do the same task.

Best of luck

 

[Airframer]

I cut a lot of foam!!!!! I spent 24 ears on AD USAF so I know foam. take chalk and sharpen it like a pencil then trace your tools in the place you want them. go to harbor freight and buy a hot knife and extra blades and have fun. I would use some scrap foam to practice on with the hot knife.

This but with two different colors of foam. contrasting color for (uncut) drawer liners, then cutout the top level of foam all the way through.

 

[CoopVA]

This but with two different colors of foam. contrasting color for (uncut) drawer liners, then cutout the top level of foam all the way through.

Just bought a 1/2" thick black yoga mat for the top and a 1/4" red yoga mat for the bottom to do just that. Got a roll of sticky back paper to trace the tools on and will cut it with a razor knife. Can do my whole box with it for less than the "official" tool chest foam costs to do two drawers...


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[BoostAddiction]

I used a hobby knife with a sharp blade. The angled, slim blade allows you to control kerf easier, and allows very fine cuts.

 

[Tyberius]

My soldering iron has a cutter head that I use.

 

[Bigplum]

So the hot knives made for cutting polystyrene work ok on the closed cell polyurethane type foam ? Does not smoke like burning building ?

 

[Hohndo]

Bigplum,

The smell (depending on the foam) can be a bit much if you do this for like an hour. You'll need a break.

Anything hot works. I've used the cheap useless knife my job provides us that I don't use for anything else as a hot knife. It's a lot easier than a traditional hot knife in my opinion. Just heat it up with a propane or map gas touch and cut to your hearts content.

I never actually thought to use a soldering knife but maybe that's because I don't like getting it dirty. I care more about clean connections than my toolbox foam.

I also just use a normal blade..it's generally just easier if you don't have much experience. Just remember to cut shorter before you cut longer. Much easier to fix a screw up if you took too little than if you took too much.

 

[Spire]

48 Pages of forum that may help...

http://www.ar15.com/mobile/topic.html?b=3&f=4&t=292695&page=1

 

[jetmechabq]

Here is some info from a great foam company that I have used in the past.

http://www.toolfoam.com/do_it_yourself.asp