Cutting foam in a pelican case

[LSU]

Who has done it and how hard was it? plus what did you use to cut it

 

[Tx_oil]

Haven't done it myself but I've read that using an electric carving knife works well.

 

[bearfutedninja]

they have a thread on this. some kind of electric heated wired i believe is what they used.

 

[Nolacopusmc]

I have cut many. I use a cardboard template and a carving knife. Keep it level and it is cheap and easy.

 

[dtd80]

I've used a electric carver with the sorta serrated blade. Pretty much cut it through well. The best I've seen is a custom hot-wire setup and after tracing and cutting, it looked like he did it from the factory. Personal preference. I think mine came out ok. I need to cut it slightly bigger.

Always cut about a half inch smaller to ensure your item will fit perfectly. You can always cut more but will have to buy another foam liner if you cut too much.

 

[BayouSlide]

Always cut about a half inch smaller to ensure your item will fit perfectly.

Excellent advice...you will likely see a little compression on the foam, unless it is super dense, with a bigger or heavy item like a rifle.

 

[SigArmed1]

I am about to do one myself and based on a suggestion from an earlier thread on this subject, I went ahead and bought a cheap "Hot Knife" from Harbor Freight and will let you know how it turns out. I figured it would make smoother cuts than an electric knife but I haven't actually used it yet to see.

 

[Narco]

that knife is **** by the hot wire

 

[SigArmed1]

that knife is **** by the hot wire

Love a good riddle!

 

[Blackhawk]

Rather than tracing an outline, it's been suggested to cut out a stencil, where everything masked is the stuff you don't want to cut, and everything you need to cut is uncovered, in the middle of the stencil.

 

[42]

The best way I have found to do a cut-out is to place the firearm in the position you wish to have it in the case, trace it out with toothpicks, take firearm out of case, line up the cutter (of your choice) with a metal ruler and trim out.

 

[dtd80]

The best way I have found to do a cut-out is to place the firearm in the position you wish to have it in the case, trace it out with toothpicks, take firearm out of case, line up the cutter (of your choice) with a metal ruler and trim out.

What I did was place my weapons/tools on the liner in a mirror fashion, then traced. I cut out about 1/2 inch shorter. THen test fitted and trimmed when necessary. After I get it clean, I flip it over so I don't see the trace markers. So if you plan on this cut it on the opposite side.( i.e. if you want the muzzle facing left, I would trace the weapon with the muzzle facing to the right so when I cut it out and flip it over, it would face left.)

 

[Shooter McGavin]

I recommend you use either a fresh straight razor, or an Exacto knife. A long straight razor is better, because you can make one continuous cut through and through the foam, whereas with a smaller length blade, you will have to make multiple passes over the same spot, which could turn out looking not so clean.

Also, I agree about the stencil mentioned above. Get a piece of cardboard and place your firearm on top. Then, trace an outline from an angle so you can get a little underneath the rifle/shotgun. It only needs to be about a 1/2 inch smaller than the firearm to ensure a snug fit. When you place the stencil over the foam to begin cutting, try your best to hold the blade at a 90 degree angle from the foam.

The hot wire idea is something I've never seen done, but it does sound feasible.

Good luck with it.

 

[bearfutedninja]

I recommend you use either a fresh straight razor, or an Exacto knife. A long straight razor is better, because you can make one continuous cut through and through the foam, whereas with a smaller length blade, you will have to make multiple passes over the same spot, which could turn out looking not so clean.

Also, I agree about the stencil mentioned above. Get a piece of cardboard and place your firearm on top. Then, trace an outline from an angle so you can get a little underneath the rifle/shotgun. It only needs to be about a 1/2 inch smaller than the firearm to ensure a snug fit. When you place the stencil over the foam to begin cutting, try your best to hold the blade at a 90 degree angle from the foam.

The hot wire idea is something I've never seen done, but it does sound feasible.

Good luck with it.

sweet username

 

[dtd80]

This is how I wanted to do mine but didn't have the time to build the hot wire setup. Farily straight forward.
http://www.ar15.com/forums/topic.html?b=3&f=4&t=292695

 

[LSU]

yeah i dont really have the extra time to do the hotwire setup

 

[Lewgee]

I have modified a soldering iron with a piece of 12ga romex to make a hot wire foam cutter before. I usually pull the ground wire out and use that.. adjust the length to get the temp right probably about 6-8" at max...and test it on a few scraps.

A good high nickel content solid guitar string works well too.

 

[ripsaw]

The best way I have found to do a cut-out is to place the firearm in the position you wish to have it in the case, trace it out with toothpicks, take firearm out of case, line up the cutter (of your choice) with a metal ruler and trim out.

Crafty got pretty close...the pelican folks tell me, place item and outline with toothpicks, then remove item and get those kids wide body chalk, and mark the connect the dots type thing, from toothpick to toothpick, but mark inside the toothpicks the full width of the fat chalk. Then when cutting it out,...with an electric carving knife..... cut on the inside of the white line of chalk......Or, ship to us and we will do it, "they said", or ship template of your set-up, or tell us your set-up...we already have many templates and will custom cut yours....for a fee of course.

 

[Nolacopusmc]

Man, I just traced the rifle out on a piece of cardboard, cut it out with razor knife and then transfered in reverse onto foam and cut with turkey knife. I think it came out slick.

Plus anytime you can use a knife and electricity in the same hand, I consider that a win. LOL