Foam rubber

**DIY DAN** · 6th January 2013, 12:17 PM

Been commissioned to make a box for a set of antique dueling pistols. What's the best material to use in the box to hold the pistols, i.e. compress the pistols into the material to make a depression then cover the depressed material with suede or similar. Any ideas?

DIY DAN

**NCArcher** · 6th January 2013, 03:53 PM

Have a read of this one Dan
https://www.woodworkforums.com/f87/knife-box-136953/

**AlexS** · 6th January 2013, 08:41 PM

Another way you can do it, probably better if it's something that's fairly thick, is as below:
Make a male mould of the piece that will go in the box
1Base & pattern.jpg
Mount the mould on a base the same size as the box will be in a temporary box and place the lining material over it.
2Pattern in box.jpg
Use expanding polyurethane foam to fill the cavity between the material and the back of the temporary box. Make sure there are holes on the back for excess foam to escape.3Inserting foam.jpg
After the foam has set, remove the temporary box. 4After foam set.jpg
Trim the excess foam from the back of the box5Insert removed from form.jpg
Voila!6Candlestick in insert.jpg

**TTIT** · 6th January 2013, 10:32 PM

There's one to try and glue to the memory bank

Thanks for sharing Alex

**DIY DAN** · 10th January 2013, 04:53 PM

Thanks for the tips guys. Will try both and see which works best.
DIY DAN

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