John J
professor emeritus
Reged: 11/05/07
Loc: Beresford SD
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Make Perfect Holes For eyepieces....How to
#2830238 - 12/29/08 07:40 AM
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If you have ever wanted to make holes for eyepieces in new foam for an eyepiece case, there is an easy way to do it. Go to you local hardware store and purchase a 2" or 1.5" (whatever size best fits your EP's) copper pipe coupler. This is a 2" coupler in the image below. Using a half round metal file, file the inside edge of one end of it to form a bevel to the outside edge making it sharp (a bit jagged too, like a serrated knife). In the image bellow you can see how it makes a knife edge on the outer edge.
http://i544.photobucket.com/albums/hh349/johnj449/DSCF0367.jpg?t=1230553946
Mark out the locations on your foam and using a rotating motion begin to apply pressure while rotating the coupler. It will cut through the foam like butter. Here is the plug it cuts.
http://i544.photobucket.com/albums/hh349/johnj449/DSCF0369.jpg?t=1230554031
After you are done you have a professional looking cut foam insert that you can be proud of!
http://i544.photobucket.com/albums/hh349/johnj449/DSCF0370.jpg?t=1230554093
Good luck on you next case project!
JJ
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Midnight Dan
Postmaster
Reged: 01/23/08
Loc: Hilton, NY, Yellow Zone (Bortl...
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Re: Make Perfect Holes For eyepieces....How to
[Re: John J]
#2830408 - 12/29/08 10:17 AM
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Great tip and nice photos! Thanks!
-Dan
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csa/montana
Den Mama
Reged: 05/14/05
Loc: montana
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Re: Make Perfect Holes For eyepieces....How to
[Re: John J]
#2830456 - 12/29/08 10:45 AM
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JJ: Since there are so many posts asking how to do this; and your post is so concise, with great photos; I've taken the liberty to add it to the Sticky at the top of the forum; "Carol's Picks".
Carol's Picks
Thank you! 
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David Castillo
Pooh-Bah
Reged: 09/09/06
Loc: Carmel Valley, Ca
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Re: Make Perfect Holes For eyepieces....How to
[Re: csa/montana]
#2830694 - 12/29/08 01:03 PM
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Thanks for the tip,JJ. I heard of a similar process, but the guy wet the foam down, and froze it to increase the density. The rational was it made a cleaner looking bore.
---
Dave
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H Rosen
sage
Reged: 09/04/08
Loc: Atlanta, GA
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Re: Make Perfect Holes For eyepieces....How to
[Re: David Castillo]
#2830729 - 12/29/08 01:26 PM
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Most hobby stores have circular cutters of various widths (2" is a standard) to drill holes in ABS plastic body shells. Typically, it's done by hand, and will make a very clean cut in almost any material. We use them to customize "blanks" for my son's nitro car collection.
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MikeCatfin
scholastic sledgehammer
Reged: 03/12/04
Loc: NJ, USA
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Re: Make Perfect Holes For eyepieces....How to
[Re: H Rosen]
#2830735 - 12/29/08 01:29 PM
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Very good tip JJ.. thanks for sharing!
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RixWorx
member
Reged: 09/12/07
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Re: Make Perfect Holes For eyepieces....How to
[Re: Midnight Dan]
#3407099 - 10/23/09 09:15 PM
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Great tip, can't wait to try it.
Rick
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csa/montana
Den Mama
Reged: 05/14/05
Loc: montana
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Re: Make Perfect Holes For eyepieces....How to
[Re: RixWorx]
#3407138 - 10/23/09 09:46 PM
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Rick, Welcome to Cloudy Nights! Glad to have you join the CN forums!
Let us know how this goes, when you try it!
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scopethis
Postmaster
Reged: 05/30/08
Loc: Kingman, Ks
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Re: Make Perfect Holes For eyepieces....How to
[Re: csa/montana]
#3407221 - 10/23/09 10:27 PM
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Very nicely done. I'm positive that your info will inspire others.
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Sky Captain
Metal Whisperer
Reged: 11/07/04
Loc: Loc: Loc:
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Re: Make Perfect Holes For eyepieces....How to
[Re: John J]
#3407341 - 10/23/09 11:37 PM
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Thanks for the how too John. I'm about to do a case of my own and will try your method. 
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john D
All you have to do is ask!!
Reged: 08/05/07
Loc: Midlothian, VA
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Re: Make Perfect Holes For eyepieces....How to
[Re: John J]
#3408625 - 10/24/09 05:39 PM
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great tip!
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Luigi
Postmaster
Reged: 07/03/07
Loc: MA
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Re: Make Perfect Holes For eyepieces....How to
[Re: john D]
#3409607 - 10/25/09 10:01 AM
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I've used cans and even plastic containers or PVC pipe or fittings, whatever had the diameter I was looking for.
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Midnight Dan
Postmaster
Reged: 01/23/08
Loc: Hilton, NY, Yellow Zone (Bortl...
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Re: Make Perfect Holes For eyepieces....How to
[Re: Luigi]
#3409969 - 10/25/09 01:25 PM
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I used this tip a while back and it worked great!
-Dan
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csa/montana
Den Mama
Reged: 05/14/05
Loc: montana
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Re: Make Perfect Holes For eyepieces....How to
[Re: Midnight Dan]
#3410827 - 10/25/09 09:14 PM
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Dan, beautiful job!
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Tim A.
scholastic sledgehammer
Reged: 09/19/07
Loc: 40 30'N 105 3'W
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Re: Make Perfect Holes For eyepieces....How to
[Re: John J]
#3446261 - 11/13/09 04:36 PM
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Something my ol' Dad taught me back when dinosaurs roamed the earth ...
A wet blade cuts rubber (including foam) far easier and more cleanly than a dry one.
I either keep dipping my hole-cutter in water, or (better yet) get the foam block dripping wet before cutting.
Tip for dummies: let the foam dry out before you put your EPs in it! 
-- Tim
Colorado
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David Allen
super member
Reged: 10/04/09
Loc: Huntsville, Alabama
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Re: Make Perfect Holes For eyepieces....How to
[Re: Tim A.]
#3450912 - 11/16/09 09:53 AM
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Next Question. Where do you get the foam to start with?
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Midnight Dan
Postmaster
Reged: 01/23/08
Loc: Hilton, NY, Yellow Zone (Bortl...
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Re: Make Perfect Holes For eyepieces....How to
[Re: David Allen]
#3450928 - 11/16/09 09:58 AM
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Quote:
Next Question. Where do you get the foam to start with?
Yonder:
http://www.foambymail.com/
http://www.foamerica.com/
-Dan
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BSJ
scholastic sledgehammer
Reged: 12/22/08
Loc: Grand Isle, VT
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Re: Make Perfect Holes For eyepieces....How to
[Re: Midnight Dan]
#3457593 - 11/19/09 06:39 PM
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Electric carving knives work well for stright cuts. They may even be on sale after thanksgiving...
I've used unmodified plastic bolt cases to make round holes. Just push and twist.
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Joe_C
member
Reged: 12/14/11
Loc: Gold River, CA, USA
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Re: Make Perfect Holes For eyepieces....How to
[Re: Midnight Dan]
#5040078 - 01/26/12 10:48 PM
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re: I used this tip a while back and it worked great!
I don't quite follow how to make the rectangular holes in your post. How are they made?
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Joe_C
member
Reged: 12/14/11
Loc: Gold River, CA, USA
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Re: Make Perfect Holes For eyepieces....How to
[Re: Midnight Dan]
#5040080 - 01/26/12 10:50 PM
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What a great case you made! 
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