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.