Custom foam inserts for hard case

[MartinBarre]

I have a Gator hard case for my RR5 which is basically a large rectangle with some foam inserts to hold it in place.

I just got one of the Charvel Desolation Stars and since it fits in the RR5 case I'm thinking I can just make up some new foam inserts for it.

I can probably get it solid enough with the existing inserts, just by packing them tight against the Star, but it would be cool if I could make some proper sized ones up with some cheap foam or polystyrene or something.

I can't be the first one to think of this, so who's done it and what did you use?

[texasfury]

.......

[MetalHeadMat]

That's a brilliant idea come to think of it. I have this spare hardshell case downstairs, I could probably take out the foam and then cut it with a bandsaw or something to match my Rhoads...

[MartinBarre]

That's a brilliant idea come to think of it. I have this spare hardshell case downstairs, I could probably take out the foam and then cut it with a bandsaw or something to match my Rhoads...

Apparently an electric bread knife cuts it great.

[MetalHeadMat]

Apparently an electric bread knife cuts it great.

Surprised I have one Thank you!

[Big Al]

I work for a company that packs components is Pelican cases and they use electric carving knives for quick cuts. Works pretty well on the soft poly and ethel foams.
May be a stupid idea...but what about the expanding foam? Spray the stuff, lay a poly sheet over it and press in the guitar. They may make different degress of hardness for the spray foam.

[MartinBarre]

Forgot I'd started this - a guy on the Seymour Duncan forum made me some up, using foam he works with. I just drew round some paper templates and posted them to him. Then, when I got the foam, I stuck some velcro strips on and, voila!



Star 2 032 by stormwatch1977, on Flickr


So I can use the same hard case for my RR5 or the Star just by switching the foam.

[Rich#6]

it was probably 20 years ago but I have taken foam and styrofoam cut it and then glued new fake fur over the top of it. looks great the way you did it.

[xenophobe]

Two methods are commonly used for cutting custom foam... use wire with a 9 or 12 volt transformer that pushes at least 1.5a, or use an electric carving knife.

[roodyrocker]

Forgot I'd started this - a guy on the Seymour Duncan forum made me some up, using foam he works with. I just drew round some paper templates and posted them to him. Then, when I got the foam, I stuck some velcro strips on and, voila!



Star 2 032 by stormwatch1977, on Flickr


So I can use the same hard case for my RR5 or the Star just by switching the foam.

That looks great! Looks like the points are well protected.

[straycat]

Hope the foam doesn't react to the paint on the body.
You could find some fur that matches the inside of the case and cover the foam.Thats what I would do make t look better.