Doing your own
tool control foam cut outs may seem intimidating, although it shouldn’t be. We
have prepared these instructions to help you cut your tool foam. You’ll be
cutting tool foam like a pro in no time if you follow these instructions!
You will need
the following tools: straight edge, tape measure, heat gun, utility knife.
Optional tools that will make the process of cutting tool control foam faster
include: plunge router, circular saw, hot knife, and carpenters square.
Step one: Take your measurements of your toolbox or
workbench that you would like the tool foam
to fit on or in. The goal is to not have space on the sides so measure to
within 1/8”.
Step two:
Cut your tool control foam to the drawer
size. You have three choices:
1) The
first is using your straight edge or square you can cut a template out of
cardboard, plexiglass, or some other easy to work with material. Drill a hole
in it and use a pin or other noninvasive item to hold the template in place
while you cut the tool foam to your drawer size.
2) Your
second choice is to mark the tool foam with your desired drawer size and using
your circular saw with guide cut a straight line. This is really only feasible
if you have a good work surface. If your work surface is the ground, go with #1
or #3.
3) Your
third choice is to mark the tool foam with your desired drawer size and using
your utility knife or hot knife cut a straight line with your straight edge or
square aiding you in keeping the drawer square.
Step three: You can cut your shapes out in a couple
different ways, its up to you as what works best for you.
1) You
can use a sharpie and trace the tools on the tool control foam in their desired
locations, once in their location use the hot knife, plunge router or utility
knife to cut out the tools shape.
2) You
can use tracing paper to trace the tools, once traced you may lay the paper on
the foam drawer, secure with tape, and cut through the paper and foam using
your utility knife or hot knife.
Step four: You will need to laminate the tool foam ½”
layer onto the ¼” layer with no cut outs. You will want to practice on some
scrap foam first. Heat the foam with the heat gun until it is tacky. Once
tacky, quickly place against another piece of foam and hold momentarily. Within
seconds the foam will be bonded. The principle is the same for laminating
drawers only in this case you will be placing the top layer on the bottom layer
and starting at one side heating up the foam in a sweeping motion from side to
side while applying pressure to the top layer of foam creating a “sandwich”
effect on the foam. Continue until you have laminated the drawer from side to
side, apply pressure as you heat the top layer and smooth on the bottom.