I'm in the process of organizing a bunch of my non-festools into systainers and I'm trying to make nice looking shaped tool inserts cut in foam.
I've acquired a meat carving knife similar to this with its double reciprocating blades for exterior and rough cutting and the Proxxon hotwire cutter like this for shaping. I also have carpet knives and normal knives like my leather man, etc. at my disposal.
Now unfortunately the hotwire cutter doesn't seem to be powerful enough for the rigid foam I bought nor does it seem to work on natural rubber (stinks to high heaven and burns the material).
As you can see, my attempts to shape a nice insert for storing my Knew Consept coping saw, Veritas dovetailing saw & some dovetail templates didn't turn out very pleasing:
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We don't have Kaizen foam here so I need to figure how to cut these nicely normally.
I've watched a bunch of videos about cutting these shapes into rigid foam and some suggest to actually cut the silhouette out first through the whole foam, then thin/shape it to measure and to glue it back into the foam bit. Is this really the way to go or are there specialized X-acto or similar blades to carve these concave shapes, standard depth cuts with straight walls etc.?
I've seen some really nicely cut inserts made by Foggers, but how do you make them?
I've acquired a meat carving knife similar to this with its double reciprocating blades for exterior and rough cutting and the Proxxon hotwire cutter like this for shaping. I also have carpet knives and normal knives like my leather man, etc. at my disposal.
Now unfortunately the hotwire cutter doesn't seem to be powerful enough for the rigid foam I bought nor does it seem to work on natural rubber (stinks to high heaven and burns the material).
As you can see, my attempts to shape a nice insert for storing my Knew Consept coping saw, Veritas dovetailing saw & some dovetail templates didn't turn out very pleasing:
[attachimg=#]
We don't have Kaizen foam here so I need to figure how to cut these nicely normally.
I've watched a bunch of videos about cutting these shapes into rigid foam and some suggest to actually cut the silhouette out first through the whole foam, then thin/shape it to measure and to glue it back into the foam bit. Is this really the way to go or are there specialized X-acto or similar blades to carve these concave shapes, standard depth cuts with straight walls etc.?
I've seen some really nicely cut inserts made by Foggers, but how do you make them?
