DIY Foam Padded Case - Router Forums
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post #1 of 18 (permalink) Old 03-10-2016, 06:35 PM Thread Starter
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Default DIY Foam Padded Case

Disclaimer: It's OK to laugh!

Recently, I bought a wireless thermometer (Maverick ET-735) for my BBQ Grill. It came in a box with no storage case. So, I thought I would make one. I searched the internet for DIY foam case, and came up with this idea.

I realized, that somewhere in the shop, I had everything I needed. After a few minutes, I found a tackle box tray that I could empty. I relocated the crank baits to other trays and I was in business.

It only took a few minutes with an oscillating tool to cut out the dividers leaving me with an empty box.

Then I laid out the pieces of the thermometer including three probes and probe brackets for the grates. I decided to cut a piee of plywood that would provide room for the probes to fit the box. I covered the transmitter with Saran Wrap to protect it just in case of a leak through.

Next I cut up a T shirt and laid it over the pieces and poked the cloth down around everything.

Next, I lightly sprayed the foam material (Great Stuff) over the entire area . After that, I cut a piece of paper and covered the foam and pressed the foam around and into all crevices. Actually, it was fairly easy. I covered the paper with a couple of pieces of plywood and sat a sand bag on top (10#).

Today, I removed the boards and discovered some squeeze out. A utility knife made quick work of that and I was done. The excess cloth was trimmed away and the new mold was fitted to the box.

Well, I'll be. It worked.

The only drawback is there wasn't enough room for the stand that the transmitter rests on when it is in operation. Other than that, I am happy. Also, one corner has a little bulge from extra foam which makes the lid hard to lock shut, but it will latch with a little effort.

Note that the foam did not bleed or leak through the T shirt material. I have some water proof stuff (Thompson's Water Seal) I plan to spray the cloth with to help make it moisture resistant.

Another note. As suggested in the original instructions, I cut a couple of pieces of dowel rod and taped them to the transmitter so it would provide a finger opening so I can easily pick up the transmitter from the mold.

I think I will make another one. The last picture shows the new box I bought at WallieWorld. This will provide the room to fit the stand in also, making a portable padded storage case.

I took a bunch of pics.

So, there you go. Here is your challenge...Get out there and make some foam filled molds for your tools or other precious stuff.

Mike
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That's my story and I'm stickin' to it!

Last edited by MT Stringer; 03-10-2016 at 06:39 PM.
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post #2 of 18 (permalink) Old 03-10-2016, 08:06 PM
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That should do it !! Plenty of padding, but I was expecting some sort of fancy wood box project. This is a woodworking forum, isn't it?

When using foam materials for box lining/padding I found that an electric carving knife borrowed from the kitchen will make nice straight cuts in the foam. It has to do with the two blades going back and forth in opposite directions, so the foam edges aren't pulled too far out of position as they are being cut.

Charley

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post #3 of 18 (permalink) Old 03-10-2016, 08:32 PM
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@MT Stringer

OK, nice job, but I gotta ask: are you bored?

Some folks call me Vince - other folks call me...........
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post #4 of 18 (permalink) Old 03-10-2016, 08:35 PM Thread Starter
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@MT Stringer

OK, nice job, but I gotta ask: are you bored?
Yes.
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post #5 of 18 (permalink) Old 03-10-2016, 10:42 PM
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Geeze, Mike. If your that bored and don't want to make the trip up here, how about getting your sketch up program out and design my bookcases and shelves. I'll send you the pics of the space, measurements, and what has to be done.

Just trying to keep you busy. lol

HJ

Does the t-shirt stay in the mold or does it peel off?
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post #6 of 18 (permalink) Old 03-10-2016, 11:15 PM Thread Starter
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Does the t-shirt stay in the mold or does it peel off?
Yes. The T shirt becomes the cover the pieces lay on.

Still waiting to fire up the pit. We have had a lot of rain the last couple of days so I practiced on the oven this evening. The thermometer works well.

That's my story and I'm stickin' to it!
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post #7 of 18 (permalink) Old 03-11-2016, 08:11 AM
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We have a wired meat thermometer that needs a case. OK, there's a good excuse to make a storage case, but I think I'll use wood. The foam is easiest to cut with a hot wire, but you can't use that with a plastic box.
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post #8 of 18 (permalink) Old 03-11-2016, 10:59 AM
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Yes. The T shirt becomes the cover the pieces lay on.

Still waiting to fire up the pit. We have had a lot of rain the last couple of days so I practiced on the oven this evening. The thermometer works well.
Whats cooking ,Mike?
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post #9 of 18 (permalink) Old 03-11-2016, 12:55 PM Thread Starter
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Whats cooking ,Mike?
My sweetie was cooking some sort of gooey cake so I set up the probe to monitor the oven temp. The cake looks and tastes like lemon bars. Pretty good, too!

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post #10 of 18 (permalink) Old 03-11-2016, 01:09 PM
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My sweetie was cooking some sort of gooey cake so I set up the probe to monitor the oven temp. The cake looks and tastes like lemon bars. Pretty good, too!
MMmmmmmm sounds good,making me hungry.

So how does that temp gauge work/ Do you put the probe in the food and set the remote on top of the stove? How does the door close with the cord going in? Have to drill a hole in the door?

Herb
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