Foam. Where do I get it?

[Jesso]

Please no smart answers.... I know there's plenty of quick wits around these parts!
I'm looking for foam to use as protection for our lighting rig.
We carry our lights around in soft cases, like these:

http://www.thomann.de/ie/arriba_cases_ac125_bag_330x330x355mm.htm

Thing is, they don't offer too much protection, and after a while the lights get bashed to bits.
So, I was thinking that I need to get some blocks of foam (think upholstery type foam that you might find in a cusion), and cut them into blocks the size of the inside of the bag, and then cut the shape (roughly) of the lights into it.... and voilla! Instant light weight cheap protection.
So I've been looking into it, and upholstery foam is pretty damn expensive. More than I want to spend anyway.
Can anyone think of any other type of foam or packing material that would do a similar job?

[lettsguitars]

polystyrene? Theres a foam seller on the indoor market in leicester where you can buy a ruck load of foam for a few quid. Surely there are similar sellers on the internet.

[waynepunkdude]

This any good?

[url="http://www.ebay.co.uk/sch/i.html?_nkw=flight+case+foam"]http://www.ebay.co.uk/sch/i.html?_nkw=flight+case+foam[/url]

[gelfin]

When you get your foam you might find the best way of cutting it is with an electric carving knife.

[Jesso]

[quote name='lettsguitars' timestamp='1339450883' post='1688816']
polystyrene? Theres a foam seller on the indoor market in leicester where you can buy a ruck load of foam for a few quid. Surely there are similar sellers on the internet.
[/quote]
Might work if I can get it in big blocks... I got some today in an electrical store (the stuff they would usually throw out) but it's all in small enough bits that it's not much use.


[quote name='waynepunkdude' timestamp='1339450974' post='1688819']
This any good?

[url="http://www.ebay.co.uk/sch/i.html?_nkw=flight+case+foam"]http://www.ebay.co.u...light+case+foam[/url]
[/quote]

Looks promising. I'd prefer big blocks of it though.


[quote name='gelfin' timestamp='1339452100' post='1688842']
When you get your foam you might find the best way of cutting it is with an electric carving knife.
[/quote]

Good advice.
Any other ideas?

[flyfisher]

Another possibility is to use expanding foam - the sort of stuff builders use for sealing gaps.

Get a plastic bag and use it to line the carrying case. Squirt a load of expanding foam into it and fold the top of the bag over (needs to be a fairly large bag). Then push the light (or other object) [u]halfway[/u] into the base of the foam-filled bag and leave the foam to set. The trick is to use enough foam to half-fill the carrying bag when fully expanded and set, so some experimentation might be needed.

Next, get another plastic bag and squirt a load of expanding foam into it. Close the top of the bag and gently push it into the carrying case over the top half of the object to be protected. Again, the trick is to use just the right amount of foam.

When set, you should have two plastic bags moulded to the shape of the object to be protected on the inside and to the carrying case on the outside.

[icastle]

[quote name='flyfisher' timestamp='1339453830' post='1688859']
Another possibility is to use expanding foam - the sort of stuff builders use for sealing gaps.

Get a plastic bag and use it to line the carrying case. Squirt a load of expanding foam into it and fold the top of the bag over (needs to be a fairly large bag). Then push the light (or other object) [u]halfway[/u] into the base of the foam-filled bag and leave the foam to set. The trick is to use enough foam to half-fill the carrying bag when fully expanded and set, so some experimentation might be needed.

Next, get another plastic bag and squirt a load of expanding foam into it. Close the top of the bag and gently push it into the carrying case over the top half of the object to be protected. Again, the trick is to use just the right amount of foam.

When set, you should have two plastic bags moulded to the shape of the object to be protected on the inside and to the carrying case on the outside.
[/quote]

+1

That's the way we've made inserts for our flightcases.

[lettsguitars]

[quote name='flyfisher' timestamp='1339453830' post='1688859']
Another possibility is to use expanding foam - the sort of stuff builders use for sealing gaps.

Get a plastic bag and use it to line the carrying case. Squirt a load of expanding foam into it and fold the top of the bag over (needs to be a fairly large bag). Then push the light (or other object) [u]halfway[/u] into the base of the foam-filled bag and leave the foam to set. The trick is to use enough foam to half-fill the carrying bag when fully expanded and set, so some experimentation might be needed.

Next, get another plastic bag and squirt a load of expanding foam into it. Close the top of the bag and gently push it into the carrying case over the top half of the object to be protected. Again, the trick is to use just the right amount of foam.

When set, you should have two plastic bags moulded to the shape of the object to be protected on the inside and to the carrying case on the outside.
[/quote]Just pray the bags dont split. You'll never remove that stuff from you're expensive equipment.

[BILL POSTERS]

Have a ring around some local re upholsterers. Comes in different grades stiffnesses and thicknesses. you'll probably find a small friendly firm that will help you out with some offcuts for a couple of quids.

[Jesso]

[quote name='flyfisher' timestamp='1339453830' post='1688859']
Another possibility is to use expanding foam - the sort of stuff builders use for sealing gaps.

Get a plastic bag and use it to line the carrying case. Squirt a load of expanding foam into it and fold the top of the bag over (needs to be a fairly large bag). Then push the light (or other object) [u]halfway[/u] into the base of the foam-filled bag and leave the foam to set. The trick is to use enough foam to half-fill the carrying bag when fully expanded and set, so some experimentation might be needed.

Next, get another plastic bag and squirt a load of expanding foam into it. Close the top of the bag and gently push it into the carrying case over the top half of the object to be protected. Again, the trick is to use just the right amount of foam.

When set, you should have two plastic bags moulded to the shape of the object to be protected on the inside and to the carrying case on the outside.
[/quote]

Going to try this. Wish me luck!

[EdwardHimself]

Boyes.

[Nibody]

Google it. There is a place that does foam cut to your spec based in wales - used it for a flight case insert for my wireless system.

**EDIT** Not the company I used - cant remember them, but these do similair [url="http://www.easyfoam.co.uk/about.php"]http://www.easyfoam.co.uk/about.php[/url]

Edited June 12, 2012 by Nibody

[flyfisher]

[quote name='lettsguitars' timestamp='1339455913' post='1688876']
Just pray the bags dont split. You'll never remove that stuff from you're expensive equipment.
[/quote]

Fair point, but it's a widely used method for protecting equipment worth far more than most music gear. First time I saw it used was as the packaging for a piece of HP test equipment that cost about £20k - and that was back in the early 80s.

But use two bags if you're really concerned and beware of any sharp corners on the item being packaged. When the foam has set it's no longer sticky, so it's only the initial moulding that has to be done with care.

Also, if the item to be protected is an irregular shape, be careful not to mould the foam around it in such a way that it can't be be extracted when the foam sets! In such cases it's an idea to first cover the item with a cardboard cover to give a smoother shape.

But be prepared for the first attempt to go wrong. My mistake was using too much foam because I didn't really know how much it would expand.

[Monckyman]

Don`t get obsessed by foam in soft cases.
Just use hard cases. Much less hassle than trying to make a soft case hard.
We carry our lights in plastic utility boxes that are light and strong and so long as the ampeg doesn`t go on top of them, will keep the lights safe.
You can line any decent box with a thin layer of foam or packing material.

[Jesso]

[quote name='flyfisher' timestamp='1339492199' post='1689084']
Fair point, but it's a widely used method for protecting equipment worth far more than most music gear. First time I saw it used was as the packaging for a piece of HP test equipment that cost about £20k - and that was back in the early 80s.

But use two bags if you're really concerned and beware of any sharp corners on the item being packaged. When the foam has set it's no longer sticky, so it's only the initial moulding that has to be done with care.

Also, if the item to be protected is an irregular shape, be careful not to mould the foam around it in such a way that it can't be be extracted when the foam sets! In such cases it's an idea to first cover the item with a cardboard cover to give a smoother shape.

But be prepared for the first attempt to go wrong. My mistake was using too much foam because I didn't really know how much it would expand.
[/quote]

Great info. Did you just use normal plastic shopping bags?

[Jesso]

[quote name='Monckyman' timestamp='1339493109' post='1689110']
Don`t get obsessed by foam in soft cases.
Just use hard cases. Much less hassle than trying to make a soft case hard.
We carry our lights in plastic utility boxes that are light and strong and so long as the ampeg doesn`t go on top of them, will keep the lights safe.
You can line any decent box with a thin layer of foam or packing material.
[/quote]

Thanks.
It's just because we already have a ton of those soft cases y'see.
I didn't want to go spending a fortune on flight cases, plus theres the weight issue.
What type of plastic boxes do you use? Don't they get smashed to bits in the back of the van"

[flyfisher]

[quote name='Jesso' timestamp='1339493357' post='1689116']
Great info. Did you just use normal plastic shopping bags?
[/quote]

Bin bags. But preferably not the really cheap thin ones, because of the above-mentioned risk of tearing during the setting process.

It doesn't really matter if the bags are too big as the unused bit can be folded back or cut off with scissors, but if they're too small and you use too much foam then you're in for a mess!

Incidentally, the foam can be added in a number of stages. Use much less than you need at first and then top-up with some more when the first lot is fully expanded and set. This will also give you practice at judging how much this stuff expands - which can be surprising if you've never used it before.

If the 'top' half of the foam ends up expanding beyond the carrying case then it's very easy to cut back down to size using a bread knife, or similar serrated blade.

Have fun!

[bremen]

[quote name='Jesso' timestamp='1339493357' post='1689116']
Great info. Did you just use normal plastic shopping bags?
[/quote]

How about those heavy rubble sacks, bit tougher.

[Monckyman]

Hi, we use the hard plastic rugged type storage containers with lids.
People use tham for moving house etc.
They aren`t indestructible, but are flexible and strong and so long as you put them on the top of the pack, are absolutely fine.
How many lights are you carrying?
We have a box large enough for 4 led par56 with a folding lid that came from some market or other, and a few storage containers that are the property of Burnley Council.(no idea..),all great for lights smoke machines,gaffa,bits of 240v extension etc.

Edited June 12, 2012 by Monckyman

[bremen]

I made a box to protect my bike on planes using this stuff:

http://www.theplasticpeople.co.uk/correx-sheet-white-4mm-x-2440mm-x-1220mm-p-130.html?utm_campaign=google-product-search-us-en&utm_medium=product_search&utm_source=google-product-search-us-en

it's like the stuff that estate agents use for their signs.

It's survived many flights. Be even tougher if you used two thicknesses with the corrugations running perpendicular. It cuts easily and is a lot lighter than plywood, so maybe something to consider as a halfway between soft bags and full flight cases?

[flyfisher]

Another thought.

I've also used those foam bedding rolls available in Millets and the like for lining carrying cases. Easy to cut to size and they are 'closed cell' so don't retain damp unlike some foam.

Lining a soft carrying case with this stuff will provide a lot of protection agains light knocks and general vibration during transit. Not as good as a full-on flight case, of course, but probably adequate if you don't throw your stuff around or chuck heavy amps on top of them.

[BassTractor]

+1 on the expanding foam. Note that you can buy foam after specified expansion ratios and pressure rates (while expanding). Technical data sheets, and sellers who know what they talk about, can help here.
As a beginner, always do the foam thing in stages, and pack the object with a daily paper or similar so you make some extra space - amongst others for being able to dress the foam with some velvety stuff afterwards. Velvety stuff is good for avoiding wear on the foam.

[BassTractor]

Also, the cell foam as used by kayak factories is great, as it is tough and semi soft at the same time, and also rather easily cut. You could ask some kayak factories where they get the stuff. For example P&H in Runcorn (between Ellesmere Port and Warrington) have great stuff, but Ireland should have enough whitewater kayakers that could help you as well.