Cutting Foam for a Flute Case

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Ben Shaffer
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Cutting Foam for a Flute Case

Post by Ben Shaffer »

So I picked up a very nice compact plastic case used for $1. There is nothing on the inside. What I would like to do is to take a piece of foam and cut the foam so it will hold the pieces of the Flute. If I can do this the Flute will fit nicely in the Case. My question is how do you get those clean perfect cuts that you see on some Flute cases that already have the foam as well as other items that already have the foam? And also where might you purchase the foam?
I know I can use an X acto Knife or Box Cutter, but will they give me the clean sharp cut I'm looking for?
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Re: Cutting Foam for a Flute Case

Post by PB+J »

You can buy foam of different type at any fabric store. It's not all that easy to work with. It will cut easily with a razor blade, except that you can't manage clean lines because it compresses as you cut it. I've sometimes clamped a board on either side of a cut I want to make, to pre-compress it. I've also used rectangular blocks of foam and hot glued them together. That works well, but you still want to get a straight consistent cut. Scissors can work. It's kind of a pain to work with.

If you use rigid insulation foam, which you can buy at Home Depot type stores in big sheets, you can score and snap it or cut it with a saw or sharp knife. It;'s very easy to shape and iy you want to get fancy yu can use a hot wire foam cutter: https://hotwirefoamfactory.com/
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Re: Cutting Foam for a Flute Case

Post by Flotineer »

For open-cell foam, the best tool I’ve found is an old-school electric turkey-carving knife. The kind with 2 blades that reciprocate. If you have one of those, you’re golden.

[ed.-spelling]
Last edited by Flotineer on Sat Jan 21, 2023 3:15 pm, edited 1 time in total.
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Re: Cutting Foam for a Flute Case

Post by bigsciota »

An alternative might be pick-and-pluck foam, chopped up into cubes already and you just pull out sections to create holes:

https://www.amazon.com/Insert-Bottom-St ... 559&sr=8-7
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Re: Cutting Foam for a Flute Case

Post by Terry McGee »

Hi Ben, all

As I've probably mentioned before, I use hot-wire cutting to a) cut down foam sheets to fit into the flute case, and b) to scoop out hemi-cylinders in the top of the block for the flute parts to live in. It's not something that you'd probably be equipped for at home, but I just mention it in case you do have access to suitable equipment. You need an adjustable source of low voltage high current power.
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Re: Cutting Foam for a Flute Case

Post by Jayhawk »

That pick and pull foam as always been a PITA to me, so I cut it with an x-acto type knife after outlining the body parts with a gold paint marker. Here are pics of what I end up with:

Image

Image

Being such a thin case (although very sturdy), I have to pluck the top down to the case to accommodate the low C/C# keys, and I have the open space up top to allow for carrying one of my O'Brien Rover whistle.

Eric
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Re: Cutting Foam for a Flute Case

Post by PB+J »

I have one of those Pelican thin laptop cases Jayhawk pictured, and I like it but the pick and pluck foam tends to kid of fall apart. There's a guy on Youtube who sprays it with that spray rubber or spray plastic stuff to keep it more in place.

Also the thin case doesn't have a handle, which bothers me. It comes with a short strap which is for me at least too short for a shoulder strap and not a good handle.
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Re: Cutting Foam for a Flute Case

Post by Jayhawk »

PB+J wrote: Tue Jan 24, 2023 12:21 pm I have one of those Pelican thin laptop cases Jayhawk pictured, and I like it but the pick and pluck foam tends to kid of fall apart. There's a guy on Youtube who sprays it with that spray rubber or spray plastic stuff to keep it more in place.

Also the thin case doesn't have a handle, which bothers me. It comes with a short strap which is for me at least too short for a shoulder strap and not a good handle.
Definitely if you like a handle, not your best choice, but if you're a backpack stuffer like me, it takes up less real estate than any other flute case I've ever owned.

Eric
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