cutting foam rubber...... ???

[Jayb]

I need to cut profiles of several handguns in 2" thick foam rubber for a pistol case to take to the range. E-bay and web searches have yielded hot wire, and scroll saw type cutters ranging in price from $10 to over $400. I'd be interested in hearing a decent way to cut these profiles without the result looking like I cut 'em with an axe.

Thanks, Jay

[Larry Ashcraft]

Friend of mine (now deceased) did it this way, I've never tried it. Soak the foam in water and freeze it. After it is frozen you can cut it with a kitchen knife.

[tankertom]

I have used an electric carving knife to great effect. The same type as used for the Thanksgiving turkey.

tt

[spin180]

I have used an electric carving knife to great effect. The same type as used for the Thanksgiving turkey.

Me too. I've used an electric knife to cut 4-5 inch thick foam and it works great.

In fact, a couple of nearby fabric outlets also use an electric knife to cut foam for customers.

:)

[Schleprok62]

I need to cut profiles of several handguns in 2" thick foam rubber for a pistol case to take to the range. E-bay and web searches have yielded hot wire, and scroll saw type cutters ranging in price from $10 to over $400. I'd be interested in hearing a decent way to cut these profiles without the result looking like I cut 'em with an axe.

Thanks, Jay


I know a guy who used a similar method... soaked and frozen, as above, but smashed it flat before freezing... used a good sharp Xacto type knife...

[ozarkhillbilly]

If its a dense heavy foam rubber then take a hacksaw blade, tape up one end of it really well for a handle and cut it with that. Then take sand paper and sand it smooth. If its a light porus foam rubber thats only 2'' thick then use scissors designed to cut meat, for a smooth cut.

Also all a hot knife is, is a bare wire that has current running through it. They are not hard to make just be real careful.

[P95Carry]

Larry - good idea that re the freezing - I have always relied on just a super sharp and large blade.

But to extend the question - I am intrigued now - while the vertical cuts are not too bad - what does anyone find best for the horizontal cuts - removing the waste to leave the recess for the gun - hopefully with a fairly flat and even surface.

Some of that is sorta cutting blind - and hard to keep uniform in that plane.

[Snagglepuss]

Good question. I was thinking about this the other day as I want to redo one of my cases. I was thinking of ordering 2 1-inch thick sheets, cutting the outline of the gun out of one and then glueing the two together. Think it will work?

[P95Carry]

Indeed, ''laminating" can I think sometimes be a great way to go - providing the final depth suits the purpose.