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Thread: Cutting foam

  1. #1
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    Cutting foam

    Do I really need to put together a hot wire for this?

    I'm only going to use it one or two times, are there any alternative methods?

    I have a Pelican 1750 on the way and the center foam piece is solid, I saw those pop-out center pieces that you simply pull sections out of but I wanted to cut out my own sections.

  2. #2
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    I have used a soldering iron before to cut Styrofoam. It should work okay, but probably not as clean as a wire cutter. Make sure you do it in a ventilated area to avoid having fumes throughout your house.
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  3. #3
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    • Buy one of those disposable razor knifes that you can snap-off the tip when it gets dull.
    • Position your item on the foam and depress slightly to hold the item stationary.
    • Extend the knife blade to the desired depth and cut around the perimeter of the item.
    • Starting at one end of the cut-out in the foam, pull up and back and begin to make slices across the full width of the foam.
    • Take your time and repeat the cuts across the foam until you have cut free that section.
    • You should now have a "shadow" in the foam where your item will sit secure.


    Some of us in aviation maintenance do this to our roll-away tool boxes as a means of tool control to prevent Foreign Object Damage (FOD) or a serious accident or incident due to a forgotten tool left on the aircraft. We call it "Shadowing A Tool Box".

    Here's an example of my AR Tool Box Shadowed.


  4. #4
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    Quote Originally Posted by Quib View Post
    • Buy one of those disposable razor knifes that you can snap-off the tip when it gets dull.
    • Position your item on the foam and depress slightly to hold the item stationary.
    • Extend the knife blade to the desired depth and cut around the perimeter of the item.
    • Starting at one end of the cut-out in the foam, pull up and back and begin to make slices across the full width of the foam.
    • Take your time and repeat the cuts across the foam until you have cut free that section.
    • You should now have a "shadow" in the foam where your item will sit secure.


    Some of us in aviation maintenance do this to our roll-away tool boxes as a means of tool control to prevent Foreign Object Damage (FOD) or a serious accident or incident due to a forgotten tool left on the aircraft. We call it "Shadowing A Tool Box".

    Here's an example of my AR Tool Box Shadowed.

    That's essentially what I did on a couple and it turned out fine. I outlined the item with the Sharpie first, then cut.

  5. #5
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    Nice! I'm going to try that, thanks.

    What are those little brass things to the right of that combo wrench?

  6. #6
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    The brass items are bubble levels. They can be seen here: http://www.weaponevolution.com/forum...M-AD-68H-MOUNT



    ETA: The "shadowing" itself is easy. The hard part is trying to explain the process in text. If you need a demonstration I could possibly put up a short video.

  7. #7
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    I've had excellent success with straight razors and electric knifes. (the kind you use to cut meat). They make nice clean cuts, straight or curved.

  8. #8
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    Nah no need for a video unless you're extremely bored, I get the idea from your post.

    I think I'm still gonna end up cutting all the way through the center foam piece so I'm gonna get a long razor and just poke and slice.

    I'm sure I can order a new piece of foam if I end up totally trashing it.

  9. #9
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    Sounds good. Just thought I'd offer!

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