French fitted Mexican lining.

[bigegg]

Busted the box on my digital bevel gauge, so I decided to make a French fitted Mexican lined box.

French fitted means that the foam is cut to hug the tool.
Mexican lining is made with UNDERLAY! UNDERLAY!

 

[bigegg]

Four pieces of underlay cut to size.
One piece is thicker to match dimensions of tool

 

[bigegg]

Cut foam to match.

 

[bigegg]

Cheap underlay doesn't work...

 

[bigegg]

Cut two layers of thinner foam instead

 

[bigegg]

Cover is piece of 5.5mm ply glued to off cut of foam

 

[bigegg]

Things to know :
I used poundland camping mats rather than underlay. (£2 a roll)

Superglue fumes when gluing this foam: not recommended!


I'll be making a 5.5mm plywood case to finish the project.

 

[mike 109444]

If you have one of those god awful soldering guns (yep I got one!) you can replace the soldering tip with a length of copper wire (length of wire from some twin and earth works well. This can then be used as a hot cut knife. Don't run it for to long due to duty cycle. Cuts polystyrene well as well.

 

[mike 109444]

Like this