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So, I was looking online for cheap medium density foam for making my own figure cases. I was shocked by the price of just plain foam. Then I got to thinking.... I replaced the memory foam 2" thick topper on my bed recently (I use it to protect the WAY too expensive 12" memory foam mattress) and realized that would make a great foam for the figs to be embedded in, and since I already got my usable life out of it, it is free. I am thinking about pickipg up some medium density 1/4 foam and gluing that to the bottoms, and making some "cookie cutters" to cut the foam into standard shapes. What do you think?

JonnyB wrote:...making some "cookie cutters" to cut the foam into standard shapes. What do you think?

What do I think? I think I would like to ask how you go about that? How do you make "cookie cutters" for foam? How would you actually employ them? A hammer & punch technique? A hole punch style? What is the cutting bit made from? This could be a splendid tutorial/article for shortcuts to DIY transport cases.



King Ghidorah

Interesting idea about the cookie cutters. If you're going to push and twist, like the fellow in this thread
http://www.dakkadakka.com/dakkaforum/posts/list/241220.page
Then they're going to have to be round, and you are probably going to have the troops standing up. Since you're working with 2 inch foam, this is probably the right way to go. I just finished making a foam cutter like his from a copper pipe fitting and it works rather well.

However, most any other shape of cookie cutter could be used to press the foam down and then a knife could be drawn around the edge to make the cut. Whatever you do, cut out the shapes before gluing it to the base sheet.

I have used the foam from matress pads before to line toolboxes for storage, I think I got one that was for a twin size bed for around 12 dollars. Lots of foam!

The cookie cutter idea is solid, but sharpened putty knives is my method of choice.

What about foam cutters? They do make open ended ones.

Eric

Well, I have now finished the move to NC, and can pay attention again. I am thinking of trying to make some simple soldered (I have the tools) cookie cutters that I will put on a wooden top (with rolled metal soldered edge embedded and glued in wood) and then do the STEP on the cookie cutter (or press hard) method. I will play with this some more very soon. I am excited to try it, as I found a really nice wheeled tote made of hard plastic at Wal-Mart for $22 that is just right for my armies I think.

John


Automatically Appended Next Post:

AesSedai wrote:The cookie cutter idea is solid, but sharpened putty knives is my method of choice.

That is a great idea. I hadn't thought of that... I may start with that...

In AUS, Clark Rubber are quite good for different foams.

You can cut furniture foam just fine with a fresh hobby blade, and that way you can have custom slots.

lord_blackfang wrote:You can cut furniture foam just fine with a fresh hobby blade, and that way you can have custom slots.

What mini range are those from?

This is Dakka dude... we shall not speak of non-GW in anything but hushed whispers in small, obscurely-placed sub-forums...

For fans of 300...

THIS IS DAKKA!!!

Ah, a time traveler from 2006.

Better than cookie cutters.... I have found a nice solution while searching online. BISCUIT Cutters. They have a metal handle, and are about 2 inches deep. Come in a variety of circular shapes....

I really like that furniture foam idea as well....


Good brainstorming. As soon as I get to the kitchen store, I will let you know how the biscuit cutters work.

I don't know. I think memory foam is pretty expensive. At least it was when I looked into getting a mattress top. However, if you have one you are just going to TOSS AWAY then of course! Try it! Foam is foam.

If it is not too thick, you can just cut it with scissors so long as you aren't too fussy about how it comes out. Other than that, no advice on this front.

I'm curious what people are thinking about regarding the cookie cutter strategy. Unless being used as a guide for a knife, cookie cutters will not work unless they are perfectly round and well sharpened.

When using the copper fittings that I use as cutters, it's the circular twisting motion that makes the hole. Simply pushing down does almost nothing.

For making differently shaped holes, I found it was best just to use the cutters I had and connect the holes with a knife or -in the case of heavy weapon squads- just to cut the shape with a knife. You can see what I did here:
http://www.dakkadakka.com/dakkaforum/posts/list/362407.page
Skip to the last post.

I'm going to be picking up a couple more copper pipe fittings in order to make larger sizes.

Confirmed... I tried the biscuit cutter right out of the packaging. It left a colored ring, but nothing else. Were I to mount it to a top board or metal bracket, and stand on it, it may cut the foam, but anything short of that does not seem to work. I do think that your pipe fitting sharpening may have to happen to the biscuit cutters as well...

Sorry to hear that. It really is the slicing motion (in this case rotation) that does the cutting work. Are your biscut cutters circles? If they are, they might work better than fittings once you get them sharpened, as pretty much any kitchen metal will likely hold an edge better than copper.

This week I bought 3 more fittings, so I have 5 different sizes. I'm also going to experiment with cutting a hole with the largest fitting and then squaring out one side of the circle with a knife so that larger models can go in on their sides.

I'll post some pics with how it turns out.

Thanks. Yes, the biscuit cutters are all circles. I bought a 4 piece set on amazon for like $6 or so, and the smallest will hold 25mm just right. I have to sharpen them and give them a try Memory foam is very resistant to cutting. at least my old one is. I just rolled the new one for moving and it split.... But, today I may get some time to sharpen the cutters. I think I said before, but these cutters have a handle so twisting will be nice for that....

Definitely let me know how it turns out. I like my copper cutters, but they do take about a half a minute of sharpening between each tray and they have no handle.

If the biscut cutters work I may pick up a set as they're not much more costly than the coppers.

I just found and am considering this:

http://www.thefoamfactory.com/packagingfoam/picknpluckcr.html

I saw that as well. Not a bad deal if you already have a case you need to fill with foam, but when compared to the price of a 10-15 case that comes with foam (the plano 1404) it's not quite as tempting.

That is a good source for that pick and pluck foam, but I still want to try my hand at making my own. Have not sharpened any cutters yet....