Hi, I want to customize my pistol case, but I can't find any info on how to neatly cut a 5/8" depression into foam that is 1.5" thick. It's not pick and pluck foam. Thanks!

Dremel with cutoff wheel.

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WWSSD?
What would Skeeter do?

Cut off a 5/8"-thick slice from the entire piece using a bandsaw. Make your cutout in the slice, then glue it back on. I've done this several times for a few cases.

Hmmmm, would the finished product look ok if I cut the pistol outlines completely through the 1.5" foam, and then take those cutouts and slice 5/8" off with a razor blade? I can then reinsert the 7/8" thick pieces back into the foam, and that would leave me with a finished 5/8" depression.

^^^ Yup... that would work too.

I would say that'd be the easiest approach if you don't have a large enough bandsaw and that 7/8" piece you reinsert doesn't need to support any weight on its own.

I don't have a bandsaw or even a Dremel tool. There will be another thick uncut foam layer beneath the cutout layer, so support should be ok.

I think slicing the 5/8" layer off the 1.5" thick cutout pieces will work since I can compress the cutouts into a manageable thickness and run the razor through in one shot.

I wouldn't do that. You'd run the risk of not getting a straight cut if you compress the foam. Get a cheap hacksaw with a thin blade.

Even if you find another method, you should buy a Dremel, everyone needs at least one of those.

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Minimize the variables

I've seen electric knives do a pretty good job of cutting foam.

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Back to back World War Champs.

I find cutting foam to be a challenge , my method is to use two layers. The bottom would be 1 inch thick and uncut. The top layer would be 1/2 inch thick and the guns profile cut out , all the way through. Set the top (cut out ) layer on the solid bottom peice and you're done. Most times the top layer doesn't move around in a case and can be easily replaced for another gun or if something else is added. But a dab of contact cement will secure them if needed.
Gary

I guess I'll have to be careful with the razor. I don't have a vise where I can secure the foam wedged in between two pieces of wood. I think a hacksaw would just rip the foam if it's unsupported.

Great advice, but I don't have the necessary tools to layer the entire piece. I have an inexpensive MTM 4 pistol case with three layers of fitted foam. I was just wondering if there was an easy way to form fit the middle 1.5" thick layer that will hold three pistols. I don't want to buy any additional foam or tools.

whichever way you go about it, cut the foam a bit inside the outline of the firearm, to make sure it sits tight against the foam.

I cut the foam today. I used a good pair of scissors to cut the shapes out, and then layered the cutouts with the scissors, so I was left with a finished 5/8" depth. The scissors cut smoother and faster than using a razor blade. Thanks for all the suggestions.

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Late suggestion. Electric carving knives work OK. How about getting two pieces of foam with the same length and width and perhaps different thicknesses than make the cutout(s) in one and tack them together?

Glad your solution is satisfactory.

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Bob

I didn't want to buy anything additional, and believe it or not, the scissors I had in a drawer for 30 years cut the 1.5" foam cleanly and layered the cutouts cleanly. It turned out pretty darn well and took 1 hour start to finish.

I got a hot wire cutter from Amazon for something like $15 and cut all the way through one layer of foam and then had a separate uncut layer under it. Can also turn the cut out piece on its edge and slice it down to size.
To make cuts in the middle of a piece I unhooked the wire and punched it through the foam before hooking it back up and applying electricity.

Few things are more satisfying than completing a project without a trip to the hardware store and spending money.

I heard someone say that there is nothing you can't make a little worse with a dremel tool. I understand that sentiment.

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God spelled backwards is dog.

where is a good source to purchase foam for a case. I'd like to make a custom case but not sure of a souce.

Maybe a fabric store

Cutting Gun Case Foam (lots of photos) -

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"He was kinda funny lookin'"

Well, I'll say it....Why cut it in the first place???????????
Put the guns in, they compress the foam when you close the case
and voila-instant snuggle up. That way you can use the case for different things. It doesn't work for something like a big old boxy camera, but for something as flat as a gun there is no need to cut out an outline other than just looking for something to do.

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Forum consigliere

Without the foam cutouts, the pistols can still slide in the case if it's disturbed enough. They can't move at all with the cutouts.

A good bread knife is my tool of choice for straight cuts on foam rubber. Works great.

Best,
Gary

Nice job. It looks as if you got exactly what you wanted.

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Oh well, what the hell.

We used electric knives to cut foam insulation all the time in the factory I manged in Florida. Works like a charm.

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Robert
SWCA #2906, SWHF #760

A cute custom fit trick is to place the items you want fitted into the bottom of the case.
Lay cloth over the case, fill it with 2 part expanding foam.
Lay a sheet of plastic, parchment, or similar over the foam, put a sheet of ply over that and add about 30 + pounds of weight.

Once cured remove the cloth covered foam block, and the items you want cased.
Flip the foam over place it back in the case and your done.

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it just needs more voltage

Here's a better pic of the cut foam using scissors for all the cutting and layering:

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