Looking for a smart bugger

I have a project I'd like to get made. I'm after someone who can draw up either a 3d print or even better get a cnc foam cut out for an ammo holder. There is a Etsy seller who has them but wants over $100 USD to ship them! They are an insert that fits in a Milwaukee Low Profile pack out box. I'm needing one for 9mm and 40cal. Pictures of the ones available overseas below so you get the gist. I'm happy to pay for someone's time and to get them done if anyone has a CNC capable of foam cuts. I know there are some clever buggers on this forum so thought I'd give it a go. I can send the Packout piece / send measurements.

Thanks in advance

I'm not a smart bugger...but if foam is cheap enough..try a case in shell holder in a drill...it may just cut your foam nicely.

message VTP victory through precision and see if they can do it

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Originally Posted by Micky Duck

I'm not a smart bugger...but if foam is cheap enough..try a case in shell holder in a drill...it may just cut your foam nicely.

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Worth a crack I spose but to be honest every time I've drilled foam, usually because it's under something I'm drilling it drills like ass.
Doesn't cut properly, very messy. The hole looks like it's been done with a screwdriver

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Originally Posted by csmiffy

Worth a crack I spose but to be honest every time I've drilled foam, usually because it's under something I'm drilling it drills like ass.
Doesn't cut properly, very messy. The hole looks like it's been done with a screwdriver

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This is my experience too. I could do a timber template that I put over the foam first, but will still see if there is a CAD /3d print option first

What's the overall dimensions of the insert you need?

Yes i would give a heads up to VTP Aidan is a cleaver bugger
What a great idea that case might have to do one my self
Cheers

Hole punch for the likes of leather or gaskets maybe? Singular punches.

Not the wheel ones.

Laser cutting.

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Originally Posted by makka

What's the overall dimensions of the insert you need?

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Shows the basics. There are the indented parts but this measure sits inside them. https://uploads.tapatalk-cdn.com/202...707e965fea.jpghttps://uploads.tapatalk-cdn.com/202...e9dc2591c0.jpghttps://uploads.tapatalk-cdn.com/202...bd047ed76f.jpghttps://uploads.tapatalk-cdn.com/202...d8fc8e6293.jpg

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Originally Posted by AR7

Yes i would give a heads up to VTP Aidan is a cleaver bugger
What a great idea that case might have to do one my self
Cheers

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They are good, and the deeper packout organisers have 3d prints for rifle calibers, garmin holders etc

https://mintworxtools.com/products/g...e-packout-copyhttps://uploads.tapatalk-cdn.com/202...3955c104d1.jpg

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skellerup ultralon (they used to sell offcutts) is your go to.
make an mdf template and chuck the foam in the freezer overnight as it tears less when cold.
then drill your heart out.

I've often thought those packout things were range clobber carriers masquerading as toolboxes. You could double layer the ammo inserts too

There are locking bar systems for them too, so you can wheel your toys to car, have it locked up (satisfying Mr Plod), and your neighbours assume you're off to help someone fit a shelf or something lol

That's a lot of stop/start for the machine,
Even thou someone does you a favour by not charging you, his/her time to draw, program and set up
water or wire cutter time alone costs a lot more than US$100
Turret (metal) or router (wood) is probably the cheapest way to go if you want to go thru cnc way,
sandwich the foam between 2 sheets to keep it steady and put it through the machine,
Or get a drilling template made up and you can drill them out in your spare time.

Chuck a case with the same exterior dimension as a 9mm in a drill press, slightly sharpen out side edge with sandpaper and use that to cut holes in the foam.
I have been looking into this at currently staying with parents who have a 3d printer, the materials are pretty cheap, however design time and printing time will be the expensive part.

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Originally Posted by Snap 4T

That's a lot of stop/start for the machine,
Even thou someone does you a favour by not charging you, his/her time to draw, program and set up
water or wire cutter time alone costs a lot more than US$100
Turret (metal) or router (wood) is probably the cheapest way to go if you want to go thru cnc way,
sandwich the foam between 2 sheets to keep it steady and put it through the machine,
Or get a drilling template made up and you can drill them out in your spare time.

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Never said I don't want to pay for time or the job getting done. What I'm not interested in is not + $100 USD for freight to get the bits here. Drilling template is an option but wont be as nice a finish as the CNC.

I would be looking at either a laser cut service (don't know of any in NZ at the moment) or a heated but very thin core cutter that moves through on a press so it's a vertical cut. A card template with the holes cut in it in the right places would act as the guide. You could even print it out on paper, glue it to a thin piece of plastic or ply and cut the guide out that way. Once you have the guide set up stick it to the foam and press away. The high density foam is not cheap in the thickness you are needing for this, and it doesn't really freeze well enough even at -4 to make rotary cutters an option for my experience. Maybe if you had liquid nitrogen on hand, but in the freezer won't do cold enough to last for the length of time you'd need to drill out that many holes.

It isn't that hard to make a cutter tip to do this, you do need the stiff ni-chrome wire or the stiffer ribbon to fashion the cutter out of and this can be a little pesky to come by. Once you have the wire, bend up a two-row coil on the bottom with two legs going up to where you need to connect the power to make it hot. When the cutter goes through, you find a balance point in rate of push through the foam where you are getting a good melted cut without cooling the cutter too much and not melting to much. Once the cutter is withdrawn you need a little punch of some sort to push the offcut out. Then onto the next hole pretty quick so the cutter head doesn't get too hot... Control of the cutter heat is a factor of resistance, commercial setups have a resistor on a control knob that does this.

I've made up a heated wire cutter for this sort of foam and the pelican case type foam to cut out tool profiles and the like, it's hand guided so not that straight but apart from the up and down and the size of the hot wire (this is under tension to keep it straight so the fine stuff is OK) the concepts are the same.

Hi @nzfubz
I don't have access to the workshop anymore but I'm happy to model up whatever you need. I think 3D printed would be better than foam but this company would be able to watercut it for you.
https://www.laserstream.co.nz/home
Here's a Pic of what a single layer printed one would look like.
Attachment 265916