How to best cut foam for an eletronics case?

[headchange4u]

I managed to get a free poker set a few weeks ago through work. The set consisted of some really nice poker chips, a couple of decks of playing card, and some dice. It also came in this really nice metal case. I immediatly had the idea that the poker case would make a great case for my iPod and accessories. It's big enough to carry my iPod, the wall charger, at least 2 small amps (my CMoy and Mint), extra batteries and any cables I might want to carry.

You can see a picture of a poker set very similar to the one I have here.

I also managed to pick up a piece of 1" foam from a radio box at work. Now I need to cut the foam so that my iPod and other accessories will have there own spot in the case.

I would like to know if you guys know the best way to cut out the foam. I would like to make this as neat and clean looking as possible, because I am anal like that. Since the case and the foam were free I also don't want to spend any money to buy some fancy foam cutting tool that I will probably never use again. Any tips or suggestion would be helpful

 

[Tril]

I suggest a very sharp knife and a metal ruler.

 

[mono]

Which is more important, that the line is straight lengthwise or squared 90' to the top and bottom plane? I mean if you "had" to pick one?

IMO, using a ruler and a straight knife to compress the foam while cutting it will make a fairly straight line but not necessarily perpendicular 90' to the top or bottom.

Elevating the foam and using a (longest available) fine-toothed serrated knife with longest strokes possible, sort-of sawing through it, will tend to make closer to 90' angles but not as straight lengthwise.

Another option that might work well if the foam has *perfect* cuts along it's outside edges is to cut individual pieces for each subsection such that the perfectly cut outside borders are then inside towards the parts, and the rougher self-cut edges are compressed up against the side of the case so they're less noticable.

 

[Francis_Vaughan]

I would second the knife and ruler. The only real alternative is a hot wire, and that is a lot of effort for little gain. Using a brand new disposable knife blade you can make very good cuts. Since none of the foam slabs are particularly thick you will be able to compress them essentially flat and then cut, yielding a close to perfect result.

 

[MASantos]

You should get an x-acto knife. they're cheap and cut really well!!

 

[bhjazz]

When I bought some thick foam from a craft/fabric store the craft witches used something that almost looked like a jigsaw. A very fine blade and a steady hand would do it.

 

[PinkFloyd]

Sharp blade cuts foam very well. I sometimes use a hot blade on the end of a soldering iron that cuts through foam like butter.