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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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: Joe_C]
#5040085 - 01/26/12 10:51 PM
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Hi Joe:
I just made those with a sharp knife. I actually used a fisherman's filet knife. Slow, careful cutting using many passes worked for me. Nice job to tackle while you're watching TV.
-Dan
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spongebob@55
sage
Reged: 12/26/11
Loc: Bergen Co. New Jersey
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Re: Make Perfect Holes For eyepieces....How to
[Re: Midnight Dan]
#5497652 - 10/31/12 12:01 PM
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Thanks Dan for your post. Where did you get the case from? I like the adjustable slots.
Sbob
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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: spongebob@55]
#5498027 - 10/31/12 04:17 PM
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Hi Sbob:
Got the case at Harbor Freight:
http://www.harborfreight.com/18-x-13-x-6-aluminum-case-69...
Not sure what you mean by adjustable slots? I made the slots to fit my eyepieces and other gear. Here's a pic of it loaded up:
-Dan
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Mike E.
Carpal Tunnel
Reged: 01/26/10
Loc: Moonstone Observatory
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Re: Make Perfect Holes For eyepieces....How to
[Re: Midnight Dan]
#5498149 - 10/31/12 05:42 PM Attachment (31 downloads)
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You can also use empty arisol cans, the wall thickness is about the same as a razorblade.
Here are a couple of photos.
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Mike E.
Carpal Tunnel
Reged: 01/26/10
Loc: Moonstone Observatory
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Re: Make Perfect Holes For eyepieces....How to
[Re: Mike E.]
#5498154 - 10/31/12 05:43 PM Attachment (32 downloads)
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Cuts a perfect hole in solid foam, and an almost perfect one in pluck foam; as shown.
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Metalmanstan
member
Reged: 07/02/12
Loc: Oneonta, NY
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Re: Make Perfect Holes For eyepieces....How to
[Re: Midnight Dan]
#5500128 - 11/01/12 11:00 PM
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May I ask how you cut the foam so you could lay the eyepieces flat instead of up and down? And is there any local retail store that I can get foam from? Did you know how deep to cut like measuring each eyepiece? It looks very amazing and I would like to try this!!
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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: Metalmanstan]
#5500465 - 11/02/12 07:04 AM
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Hi Metanmanstan:
For the rectangular cuts I just use a very sharp, stiff knife like a fishing filet knife and take my time. I cut the rectangular plug all the way through the foam to start with. If I need a hole that is not the full depth, then I cut a slice off the bottom of the plug and put it back in the bottom of the hole.
I couldn't find any local stores for the foam so I bought it online. Links are in my posts above.
-Dan
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Mike E.
Carpal Tunnel
Reged: 01/26/10
Loc: Moonstone Observatory
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Re: Make Perfect Holes For eyepieces....How to
[Re: Midnight Dan]
#5500468 - 11/02/12 07:10 AM
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Foam remnants, large enough for eyepiece cases are often available at upholstery shops.
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star drop
Snowed In
Reged: 02/02/08
Loc: Snow Plop, WNY
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Re: Make Perfect Holes For eyepieces....How to
[Re: John J]
#5500546 - 11/02/12 08:43 AM
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 For vertical eyepiece storage take your eyepieces, load them into a rail gun and blast them through the foam.  Perfect holes every time. Remember to fold the eye cups down first. 
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Tom McDonald
sage
Reged: 12/19/06
Loc: No where man!
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Re: Make Perfect Holes For eyepieces....How to
[Re: BSJ]
#5502738 - 11/03/12 06:01 PM
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"Electric carving knives work well for stright cuts. They may even be on sale after thanksgiving..."
They still make and sell them?? 
Haven't seen one since I guess the '60's or early '70's!
Never missed the one my mother bought way back when. I'd rather use a "real" knife! 
Didn't mean to hijack the thread...I'm old. 
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okieav8r
Carpal Tunnel
Reged: 03/01/09
Loc: Oklahoma!
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Re: Make Perfect Holes For eyepieces....How to
[Re: Tom McDonald]
#5503324 - 11/04/12 01:10 AM
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You can get electric carving knives at Walmart for $10 in the kitchen section. I use them for cleaning fish, and they beat heck out of the overpriced Rapalla knives and others that are supposedly made for fishing.
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