Cutting Foam For Tool Storage

[need4speed]

So I’m trying to get my tools organised. I recently purchased a nice Pelicase Tool Box. It has several drawers and has foam in each.

I contacted a company called Paulamar and sent them pics of how I’d like the tools organised etc. They wanted £277 to cnc cut 2 drawers!!! Don’t think so..

I then tried just cutting round the tools with a scalpel etc but it looked like ****.

Anyone know of a company that would be cheaper than above? Or any other ideas?

[TSD]

I assume it doesn't have the 'pick and pluck' foam that most peli cases have? Those are supplied partially cut in a ~10mm grid, so you can just draw round the items and tear out the foam as required.

It doesn't seem like it would be hard wearing enough for a toolbox, so not surprised if it isn't.

The company I used to deal with for that type of thing used multiple layers of foam bonded together, with a thin fabric covered layer on the top. I can imagine that being easier to make a decent job of by hand , because only the top layer has to be really neat.

Vacuum forming a top sheet maybe, or just 3d print the whole thing in sections, depending on tool size (stop sniggering at the back!)

I'd be certain of remembering one more tool, just after I'd finished, so knowing that  I'd just never start

[need4speed]

Yes you are correct, the smaller Peli cases I have use the pick n pluck foam but not this case. The foam is made of a twin colour material that is a lot firmer (easier to cnc) than the pick n pluck.

 

[landroversforever]

I’ve only ever cut shadow foam with a scalpel which has done it neatly. Just more awkward to make the cutouts level/square on the bottom face. 

[FridgeFreezer]

The companies that do it use a CNC router with a razor-sharp bit that spins effing fast, hence why they can get it so neat.

I'm not entirely sure there's a DIY option other than buying the cheapest 6040-style CNC router you can find and going at it - likely to be similar cost to the quote you had but you do get a free router out of it

https://www.ebay.co.uk/itm/276564708497

For example

[Snagger]

Would a hot wire like used in cutting expanded polystyrene just make a burnt mess?  Could be worth a try.

[landroversforever]

I should add that when I've done it with a scalpel in the past I had to make sure it was a brand new one out of the packet. 

[need4speed]

Kudos to you Ross. Mine looked utter gash

[need4speed]

10 hours ago, FridgeFreezer said:

The companies that do it use a CNC router with a razor-sharp bit that spins effing fast, hence why they can get it so neat.

I'm not entirely sure there's a DIY option other than buying the cheapest 6040-style CNC router you can find and going at it - likely to be similar cost to the quote you had but you do get a free router out of it

https://www.ebay.co.uk/itm/276564708497

For example

If only I knew where to even begin with programming that to cut the tool shapes. 

[ThreePointFive]

8 hours ago, Snagger said:

Would a hot wire like used in cutting expanded polystyrene just make a burnt mess?  Could be worth a try.

I thought this, but I'm not sure the foams are stable enough at high temperature and won't just turn into a crusty bubbly mess. 

I've spent some time today doing some foam cutting and it looks like the aforementioned 'utter gash'. The secret seems to be tape to mark out the shape and make it easier to follow the line, a sharp scalpel and immediate, extreme competence. 

I cannot stress enough how important that last factor is, because it's what I'm missing. 

It took me a bit longer than I'd like to admit to work out you can make the cutouts padded by cutting all the way through and then cutting the bit you remove to the depth required, then put them back. 

[landroversforever]

If it’s like shadow foam, it should be layered so you drop the tool on cut round and then you can peel the layers out to get the right depth. 

[Superpants]

I have done a bit of foam cutting, the trick is a really sharp blade, you would be looking at giving it a quick hone up every few minutes. The other option is a band saw, can be very effective

This should be a good start!

Edited yesterday at 10:29 AM by Superpants

[Superpants]

And this one too.

https://m.youtube.com/watch?v=yE_JXfQ-1lc

[FridgeFreezer]

Another option would be buy the 2 colours of foam separately, cut the top layer out and then glue it to the underneath - no need to neatly pluck then.

[pete3000]

Flatbed document scanner and a desktop laser cutter? obviously choice of foam is key, but could be done in layers of 4-6mm and glued to make thicker sheets.

Flatbed scanner or camera to take a photo against black background as a B&W image then scale and cutout of foam

[Bowie69]

What's wrong with just throwing them in a drawer and shutting it out of sight 

[miketomcat]

3 hours ago, Bowie69 said:

What's wrong with just throwing them in a drawer and shutting it out of sight 

And you can get a lot more in a draw if there's no foam in it.

[Jon White]

An electric carving knife is superb for cutting foam, but may not be small enough for what you are trying to achieve