Router bit storage expansion

[cfullen]

What is the best way to cut through the foam that comes in the router bit systainer?  I mostly have 1/2" shank router bits and there is a large amount of dead space.  I'd like to make some more 1/2" diameter holes

 

[wow]

Leather punch?

Actually, I'm interested in a good answer as well...

 

[cfullen]

I thought about heating up some 1/2" steel and burning through it. 

 

[batcave]

Use a drill bit. It works just fine.

 

[tallgrass]

I took an old hole saw that was burned up and sharpened it. Works great. Did the same with old saws all blade for cutting foam. For the small battery powered saws all.

 

[tbellemare]

I've never tried it but I think you want a smaller hole than 1/2" to hold the bits tightly. Maybe, 7/16, or 12mm? Just drill it slowly with a sharp bit?

I'm thinking that if you dwell at all in that material, it will just melt.

Tom

 

[Bob Wolfe]

Try taking a short piece of 1/2 in copper pipe, sharpen one end on a grinder or sander, use as a hole punch, should cut foam cleanly.  BW

 

[wow]

Try taking a short piece of 1/2 in copper pipe, sharpen one end on a grinder or sander, use as a hole punch, should cut foam cleanly.  BW

Good idea, but pretty sure 1/2" pipe would be too big. Maybe 3/8" ?

 

[cfullen]

I'm going to try with a sharp drill bit first.  If that doesn't work to my liking, I am going to try a hole saw.  Last ditch effort, i will use the copper pipe theory.  I will keep you guys posted with my progress.

 

[nclemmons]

I use brass tubing that you can buy in a hardware store,  comes in 1/4, 3/8, 1/2 inch diameters.  Put on a drill and use sandpaper to sharpen the outside edge.  Foam easily pulls out and the holes look factory quality.

Neil