Solid "foam" choices

[Don Y]

Hi,

I have several "cases" that I'd like to convert into
carrying cases for various tools that seem to keep
multiplying around here. (primarily hand tools)

I figure all I need to do is find some reasonably stiff
"foam" in which I can cut holes to set the individual
tools in, then place these in the cases. Not as good
as a case made *specifically* for a particular tool
but a lot better than storing tools in generic cardboard
boxes!

Most of the "foam" I've encountered at craft stores is
just that -- foam. Spongey. It should be easy to
manipulate but I doubt it will offer much support to
the tools once the case is closed and carried off.

[Styrofoam is too "brittle" IMO. But, reasonably "firm"]

The carrying case for one of my LCD projectors has a "foam
filler" that seems perfect. *Looks* like styrofoam
(contrast that with the sort of foam with which you would
stuff a seat cushion) but rubbery-er. And black.

I.e., unlike the "seat cushion foam", it has very little "give"
(just like styrofoam). Unlike styrofoam, it doesn't fall apart
when abused!

Suggestions as to what I could use and where I might find it?

Thx,
--don

 

[Lasse Langwadt Christensen]

Den torsdag den 5. december 2013 19.49.31 UTC+1 skrev Don Y:

Hi,



I have several "cases" that I'd like to convert into

carrying cases for various tools that seem to keep

multiplying around here. (primarily hand tools)



I figure all I need to do is find some reasonably stiff

"foam" in which I can cut holes to set the individual

tools in, then place these in the cases. Not as good

as a case made *specifically* for a particular tool

but a lot better than storing tools in generic cardboard

boxes!



Most of the "foam" I've encountered at craft stores is

just that -- foam. Spongey. It should be easy to

manipulate but I doubt it will offer much support to

the tools once the case is closed and carried off.



[Styrofoam is too "brittle" IMO. But, reasonably "firm"]



The carrying case for one of my LCD projectors has a "foam

filler" that seems perfect. *Looks* like styrofoam

(contrast that with the sort of foam with which you would

stuff a seat cushion) but rubbery-er. And black.



I.e., unlike the "seat cushion foam", it has very little "give"

(just like styrofoam). Unlike styrofoam, it doesn't fall apart

when abused!



Suggestions as to what I could use and where I might find it?



Thx,

--don

layers of sleeping pad ?

http://en.wikipedia.org/wiki/File:Mattress.jpg


-Lasse

 

[Clifford Heath]

I have several "cases" that I'd like to convert into
carrying cases for various tools that seem to keep
multiplying around here. (primarily hand tools)
I figure all I need to do is find some reasonably stiff
"foam" in which I can cut holes to set the individual...
Suggestions as to what I could use and where I might find it?

Go to an upholsterer's supplier and buy polyurethane foam of the
appropriate density.

 

[Spehro Pefhany]

Hi,

I have several "cases" that I'd like to convert into
carrying cases for various tools that seem to keep
multiplying around here. (primarily hand tools)

I figure all I need to do is find some reasonably stiff
"foam" in which I can cut holes to set the individual
tools in, then place these in the cases. Not as good
as a case made *specifically* for a particular tool
but a lot better than storing tools in generic cardboard
boxes!

Most of the "foam" I've encountered at craft stores is
just that -- foam. Spongey. It should be easy to
manipulate but I doubt it will offer much support to
the tools once the case is closed and carried off.

[Styrofoam is too "brittle" IMO. But, reasonably "firm"]

The carrying case for one of my LCD projectors has a "foam
filler" that seems perfect. *Looks* like styrofoam
(contrast that with the sort of foam with which you would
stuff a seat cushion) but rubbery-er. And black.

I.e., unlike the "seat cushion foam", it has very little "give"
(just like styrofoam). Unlike styrofoam, it doesn't fall apart
when abused!

Suggestions as to what I could use and where I might find it?

Thx,
--don

http://www.uline.com/BL_863/Convoluted-Foam-Sets

http://www.uline.com/BL_873/Pick-And-Pack-Foam




Best regards,
Spehro Pefhany

 

[Don Y]

Hi Clifford,

Go to an upholsterer's supplier and buy polyurethane foam of the
appropriate density.

I thinnk that is likely to be the same sort of "spongey foam"
that I've found at craft stores -- various thicknesses, various
stiffness. But, none would hold up to, for example, cradling a
10 pound sledge hammer, circular saw, sawzall, etc.

[yes, they would keep it from bouncing around in the case, but
the "foam" would quickly show signs of deformation]

The stuff I'm looking for is more like styrofoam in appearance and
consistency (your foam looks like a bunch of little bubbles
welded together; styrofoam looks like a bunch of little *blobs*
welded together (sorry, I can't come up with a better way of
describing them -- look at them side by side....). But, the
stuff I'm after is much rubberier than styrofoam. It doesn't
"chip off" like styrofoam does when you "pick at it".

I should see how well it photographs -- though that still wouldn't
convey its texture, mechanical properties, etc. But, you could
see how "hard" an edge it holds, that you could pour water on it
and it wouldn't seep in, that I can set a 10 pound sledge on it
you'd not be able to tell *where* it sat *while* it was there or
after it had been removed! (i.e., REALLY stiff)

 

[Don Y]

Hi Spehro,

Most of the "foam" I've encountered at craft stores is
just that -- foam. Spongey. It should be easy to
manipulate but I doubt it will offer much support to
the tools once the case is closed and carried off.

[Styrofoam is too "brittle" IMO. But, reasonably "firm"]

The carrying case for one of my LCD projectors has a "foam
filler" that seems perfect. *Looks* like styrofoam
(contrast that with the sort of foam with which you would
stuff a seat cushion) but rubbery-er. And black.

http://www.uline.com/BL_863/Convoluted-Foam-Sets

http://www.uline.com/BL_873/Pick-And-Pack-Foam

The first one I'm sure is the wrong sort of foam -- it's
very much like the stuff they sell in craft stores to make
cushions.

Second one I am assuming is similar -- just sliced and
diced differently?

Think of (or, better yet, *hold* a piece in your hand!)
that sort of foam. Then, think of styrofoam. They are very
different in terms of their physical characteristics.
I.e., styrofoam isn't *intended* to be elastic. When you
exceed a certain pressure, it deforms permanently. The
other foam "always" deforms under load -- yet returns
(normally).

What I'm looking for is closer to styrofoam but less flimsy.
It feels like it has rubber in it -- though looks much like
styrofoam (and not at all like the springy/spongey foam.

Said another way, I could cut styrofoam (and this
stuff I am looking for) with a sharp knife. The foam you
cite above would tend to deform under the pressure of that
knife! (you'd need a heated blade or an *extremely* sharp
blade to cut along an intended "line")

I need to see if this photographs well...

 

[Ecnerwal]

I can set a 10 pound sledge on it
you'd not be able to tell *where* it sat *while* it was there or
after it had been removed! (i.e., REALLY stiff)

And a real upholstery supply has PU foam that is that stiff; not just
the squishy stuff. Floral supply has another stiff-foam variant, but
it's generally white or green.

However, a fully form-fitted stiff solution is also available. Two
sheets of plastic film larger than the case, and a can of spray PU -
Great Stuff (tm) or the like. Spray case, lay film, lay tools, lay film,
spray top of case, close, wait. A few vent holes will make the need to
judge the proper amount of foam slightly less picky - cut off what boils
out. You can even get black, if you want it. DON'T get latex "foam."

 

[miso]

Hi,

I have several "cases" that I'd like to convert into
carrying cases for various tools that seem to keep
multiplying around here. (primarily hand tools)

I figure all I need to do is find some reasonably stiff
"foam" in which I can cut holes to set the individual
tools in, then place these in the cases. Not as good
as a case made *specifically* for a particular tool
but a lot better than storing tools in generic cardboard
boxes!

Most of the "foam" I've encountered at craft stores is
just that -- foam. Spongey. It should be easy to
manipulate but I doubt it will offer much support to
the tools once the case is closed and carried off.

[Styrofoam is too "brittle" IMO. But, reasonably "firm"]

The carrying case for one of my LCD projectors has a "foam
filler" that seems perfect. *Looks* like styrofoam
(contrast that with the sort of foam with which you would
stuff a seat cushion) but rubbery-er. And black.

I.e., unlike the "seat cushion foam", it has very little "give"
(just like styrofoam). Unlike styrofoam, it doesn't fall apart
when abused!

Suggestions as to what I could use and where I might find it?

Thx,
--don

The foam you describe is what I find when I buy military surplus transit
cases. I have never seen it at a foam shop. But the foam shop I use gets
pretty close, and I prefer a softer foam anyway.

I saw the suggestions about an upholstery shop, and that is where I
wouldn't go. In most industrial areas, they have foam shops that stock a
variety of foams.

Granger has foam, but you probably won't like the price. You are better
off finding a local foam shop and eventually one will have what you want.

The shop I use cuts to spec. I glue the foam to the case using a 3M
spray on glue. Super 77 will work.

 

[Martin Brown]

Hi Clifford,

Go to an upholsterer's supplier and buy polyurethane foam of the
appropriate density.

I thinnk that is likely to be the same sort of "spongey foam"
that I've found at craft stores -- various thicknesses, various
stiffness. But, none would hold up to, for example, cradling a
10 pound sledge hammer, circular saw, sawzall, etc.

[yes, they would keep it from bouncing around in the case, but
the "foam" would quickly show signs of deformation]

The stuff I'm looking for is more like styrofoam in appearance and
consistency (your foam looks like a bunch of little bubbles
welded together; styrofoam looks like a bunch of little *blobs*
welded together (sorry, I can't come up with a better way of
describing them -- look at them side by side....). But, the
stuff I'm after is much rubberier than styrofoam. It doesn't
"chip off" like styrofoam does when you "pick at it".

I should see how well it photographs -- though that still wouldn't
convey its texture, mechanical properties, etc. But, you could
see how "hard" an edge it holds, that you could pour water on it
and it wouldn't seep in, that I can set a 10 pound sledge on it
you'd not be able to tell *where* it sat *while* it was there or
after it had been removed! (i.e., REALLY stiff)

The stuff you want is one of the Stratocell polyethylene foams used to
cushion expensive gear in transit from the likes of UPS jugglers.

See for example:

http://www.foampackaging.co.uk/foam-types/

 

[Clifford Heath]

I think that is likely to be the same sort of "spongey foam"
that I've found at craft stores

You're thinking of latex foam. It's rubbish.
Ask for high-density PU foam and you'll get what you want.

 

[Clifford Heath]

I saw the suggestions about an upholstery shop, and that is where I
wouldn't go.

Here in Australia, it's about a half the price, and three times the
quality of what you can get elsewhere. It's where good auto trimmers and
professional re-upholsters go, so it's sold at trade prices.

 

[Don Y]

On 12/5/2013 10:49 AM, Don Y wrote:

The foam you describe is what I find when I buy military surplus transit
cases. I have never seen it at a foam shop. But the foam shop I use gets
pretty close, and I prefer a softer foam anyway.

I've never bought any military surplus cases. But, this would be
in the same category as an "equipment case" for a relatively high
end piece of kit. *Heavy* kit. E.g., I have carrying cases for
professional microphones that are filled with the "spongey"
foam that I mentioned. It's appropriate, there, as the microphones
are pretty lightweight.

I saw the suggestions about an upholstery shop, and that is where I
wouldn't go. In most industrial areas, they have foam shops that stock a
variety of foams.

I will contact some of the hits google turned up for "foam" later
today. I can always bring in what I have as a sample and say,
"Gimme some of this" or "Can you tell me what the heck this is?"
However, I don't expect to get much in terms of results.

Granger has foam, but you probably won't like the price. You are better
off finding a local foam shop and eventually one will have what you want.

There's a Grainger in the general part of town I'll be in. I can
always stop in and see if they have the equivalent product, regardless
of price. Then, jot down what they *call* it and use that to locate
another vendor.

The shop I use cuts to spec. I glue the foam to the case using a 3M
spray on glue. Super 77 will work.

This stuff is so rigid that I suspect I can almost *wedge* it in place!
E.g., When I pulled it out (despite the adhesive), I've been able to
push it right back into place, turn the case upside down, shake it, etc.
It *really* doesn't like being compressed so squeezing it just a little
(to get it past whatever "lip" surrounds the case top/bottom) and then
letting it return to its normal size seems to hold it in place well.

 

[George Herold]

Hi,

Hi Don, We have use this stiff but 'plasticy' white foam.
It's easy to cut, but holds up to all sorts of pressure.

No sledge hammers here, but some pictures

https://www.dropbox.com/s/hn8b2p9dlkwddny/DSCF0050.JPG

https://www.dropbox.com/s/g3w2imgyu2zffx7/DSCF0051.JPG

I can't find the name of the foam right away.. but if that's what you are looking for I can contact our packaging people and see what's it's called. It comes in various thicknesses and we sometime 'glue' pieces together.

George H

 

[Don Y]

Hi George,

On Thursday, December 5, 2013 1:49:31 PM UTC-5, Don Y wrote:

Hi Don, We have use this stiff but 'plasticy' white foam.
It's easy to cut, but holds up to all sorts of pressure.

Yeah, I think that's the stuff Martin (?) was talking about.
It's kinda "shiney" (has a glossy finish vs. the matte finish
that styrofoam can be thought of having)? And almost feels
"wet"? I've frequently seen that as a "skeleton" around items
that are packed in cardboard boxes.

(I.e., when styrofoam was used for that, you typically had large
conformal fitting blocks of styrofoam being used. The stuff you
are talking about seems to be used more sparingly and, as you
say below, almost like it is glued together from more nominally
dimensioned "stock" pieces (instead of the more "custom"
approach used by styrofoam)

No sledge hammers here, but some pictures

https://www.dropbox.com/s/hn8b2p9dlkwddny/DSCF0050.JPG

https://www.dropbox.com/s/g3w2imgyu2zffx7/DSCF0051.JPG

I can't find the name of the foam right away.. but if that's
what you are looking for I can contact our packaging people and
see what's it's called. It comes in various thicknesses and we
sometime 'glue' pieces together.

This is a photo of the stuff I'm looking for. That's a 10lb sledge
sitting "end on" the foam. Note that there is virtually no deflection
(I was tempted to take a picture with me *standing* on it to really
illustrate how firm it is)

Note that it isn't as homogenous looking as your stuff or the stuff in
the second photo, below. I describe it as looking like (black) "large
curd" cottage cheese! :-/ And, where styrofoam feels "dry" and your
stuff "wet", this stuff feels like "rubber" (but I don't think it is)

http://www.mediafire.com/view/dqio6bt0d9rlsjr/Stiff.JPG

By contrast, below is some of the foam that Spehro had mentioned (I
think). Note that you can't even *see* the end of the hammer as
it has sunk so far into the foam!

http://www.mediafire.com/view/4mm58g4bjlxg223/spongey.JPG

I'll start calling foam places this afternoon. Too early to be
working! :>

 

[Don Y]

This is a photo of the stuff I'm looking for. That's a 10lb sledge
sitting "end on" the foam. Note that there is virtually no deflection
(I was tempted to take a picture with me *standing* on it to really
illustrate how firm it is)

I deliberately didn't downsample the photos so you can zoom in to see
a bit more detail. Black on black tends to be a bit vague...

 

[Don Y]

Hi Clifford,

You're thinking of latex foam. It's rubbish.
Ask for high-density PU foam and you'll get what you want.

I'm not hopeful -- but I will try. I can't imagine this stuff
being used in any sort of "compressible" application! It's
just too stiff. (Can you imagine using styrofoam in that way?)

 

[Don Y]

Hi Joe,

It sounds like you are looking for polyethylene foam.

Polyurethane foam is usually quite fragile, and turns to crumbs.
Polyurethane foam can also revert to urethane resin, a gooey mess.

The black stuff is probably carbon loaded polyurethane.

I'm not sure. I thought polyethylene foam was more homogenous.
See my photos elsewhere this thread.

I'm not sure if the color isn't just for cosmetic reasons (?)

 

[miso]

Here in Australia, it's about a half the price, and three times the
quality of what you can get elsewhere. It's where good auto trimmers and
professional re-upholsters go, so it's sold at trade prices.

The problem is upholstery shop foam is too soft. We can get that foam at
Wal-Mart. For light stuff, that is what I use.

For a lot of mobile radios/scanners, the USAF night vision transit boxes
are just about the right size as is.

http://www.murphyjunk.net//wp-content/uploads/2013/05/PVS14CC1.jpg

I have half a dozen of these cases. I got them at a swap meet for $6,
but Murphy's price isn't all that bad. Every one I got is air tight. I
can barely open them after dropping in altitude.

 

[George Herold]

Hi George,

http://www.mediafire.com/view/dqio6bt0d9rlsjr/Stiff.JPG

Hmm OK I don't know what that is.

Here's a pic of me standing on the white foam.
It comes in all sorts of different hardness's and open or closed cells.
https://www.dropbox.com/s/ban8qucq9lfy7gy/DSCF0053.JPG

https://www.dropbox.com/s/x55yyk0kcwikf8g/DSCF0056.JPG
(Sorry I wore my boots today.. there's an ice storm on the way.. "Be prepared".)

George H.

 

[Clifford Heath]

I'm not hopeful -- but I will try. I can't imagine this stuff
being used in any sort of "compressible" application! It's
just too stiff. (Can you imagine using styrofoam in that way?)

The stuff I bought for lining a flight case is 1.5" thick, and the kind
of stuff that you could stand on one-legged all day without it going
completely flat, and when you hop off, within 5 seconds there'll be no
sign that you did it. And that's not the densest stuff they make.

Upholsterers need and use all grades, often with lower density glued
over higher density foam. I've seen the light stuff that miso talks
about too, but a trade supplier - especially that supplies pleasure
boat chandleries and trimmers - will have the good stuff.

But it seems you like questions more than you like answers...
Find a proper trade supplier and don't take "no" for an answer.

Clifford Heath.