Cutting Foam Inserts

[Staniam]

Hey guys, I was wondering what your thoughts are for best cutting your own foam inserts for tools and systainers. I bought two 2x2 3" thick foam pads from Home Depot and will be using them as inserts in some systainers. Each pad was only $5.

Looking for your advice on cutting them.

 

[Corwin]

I'm sure there are plenty of threads here on the subject that you might find with a search. But right off hand, here's a link to FastCap's Kaizen Foam page where they have plenty of information and videos.

 

[Staniam]

I'm sure there are plenty of threads here on the subject that you might find with a search. But right off hand, here's a link to FastCap's Kaizen Foam page where they have plenty of information and videos.

I've used their foam before but it never dawned on me to check out their site. I was thinking there would be some special tool to cut but thats just a long utility knife by the looks of it. Thanks!

 

[travisj]

I have used the Kaizen foam quite a bit.  It is very easy to work with.  I always have used a pattern marker and just a couple of disposable utility/carpet style knives.  I have seen videos where people have taken a heated pipe to "cut" a curved recess for a finger pull.

 

[caseman]

I've done enough foam work in the past 15 years to fill a battleship.  Use chalk or a white/silver Sharpie on the backside to outline the proposed cut.  The best method is to use a bandsaw with 1/8" or 1/4" blade
to enter, cut the outline, exit same entry slot.  Spray both surfaces with a 3M type adhesive, let dry to tacky to touch, close seam, do this from top so you can get surfaces level.  A kitchen electric carving knife works well and will not harm the carving knife.  An electric carving knife to dedicate to the shop is about $10 USD.

Don