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Kaizen Case Foam Source - Cheap!

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18 replies to this topic

#1 MarkMittlesteadt

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Posted 27 September 2022 - 10:21 AM

I recently purchased an AT72ED-II refractor and it's the first new scope I've bought in over 30 years!. So, of course I want to protect it. Normally I'd just used a toolbox and pack it with cheap foam, but I love the scope and it deserves a great case for it. I've looked at the Apache 4800 which would fit everything (scope and ALL my accessories), but I don't like the soft "pluck" foam.

 

I have a hardshell lockable briefcase/laptop case that has the exact same dimensions as an Apache 4800 case. I've ripped out all the old remaining soft foam on the bottom and removed the pocket from the lid. Here's my layout which is going to change, but everything fits! I just need foam.

 

6f106c_12d4ac3bc4fc432e83845b7342176643~

 

I have been looking all over online for foam for a scope/accessory case. I really wanted Kaizen foam but for how much I need, most places sell it for almost as much as an Apache 4800 case with pluck foam! 

 

But...I found a source with a great price. Home Depot Kaizen Foam. They sell it in 24' X 48' X 2.25' sheets. That can be cut down to three 16" X 24" X 2.25" sheets. That's enough to completely fill an Apache 4800 case!

 

I can take one of the 16" X 24" X 2.25" sheets and peel it apart for the lid and base, still having two full size 2.25" thick pieces left for the middle layers. I'm so glad to have stumbled on Home Depot because the next cheapest place sold what I needed for almost $60!!! shocked.gif


Edited by MarkMittlesteadt, 27 September 2022 - 10:53 AM.

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#2 wrvond

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Posted 27 September 2022 - 10:26 AM

That's where I get all my Kaizen foam. Don't waste your money on their fancy knife, though. It's worthless. Mine broke the first time I tried to use it. Instead, get a DeWalt DW10038 utility knife from the same store.


Edited by wrvond, 27 September 2022 - 10:26 AM.

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#3 MarkMittlesteadt

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Posted 27 September 2022 - 10:29 AM

That's where I get all my Kaizen foam. Don't waste your money on their fancy knife, though. It's worthless. Mine broke the first time I tried to use it. Instead, get a DeWalt DW10038 utility knife from the same store.

I've cut Kaizen foam before. It cuts pretty clean with a serrated steak knife too!


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#4 eyeoftexas

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Posted 27 September 2022 - 10:56 AM

I got my Kaizen foam from Rockler (https://www.rockler.com/).  Definitely the DeWalt knife works well, although the steak knife is genius.


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#5 MarkMittlesteadt

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Posted 27 September 2022 - 12:14 PM

I got my Kaizen foam from Rockler (https://www.rockler.com/).  Definitely the DeWalt knife works well, although the steak knife is genius.

Not really genius. More like it's all I had to work with. We had an electric turkey carving knife that worked great, but the wife got rid of it in a garage sale. lol.gif


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#6 mikerepp

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Posted 27 September 2022 - 12:20 PM

I use a electric carving knife to cut foam works great.


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#7 wrvond

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Posted 27 September 2022 - 12:44 PM

I've used the electric knife for cutting soft foam, but with the rounded tip you can't really make plunge cuts like you can with the pointy utility (or steak) knife.


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#8 pj_thomas

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Posted 27 September 2022 - 12:56 PM

I've cut Kaizen foam before. It cuts pretty clean with a serrated steak knife too!

You can wet it then freeze it and use power tools. 


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#9 MarkMittlesteadt

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Posted 27 September 2022 - 01:02 PM

You can wet it then freeze it and use power tools. 

LOL. I'm imagining my wife asking what that large slab of black meat is in the freezer. lol.gif


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#10 MarkMittlesteadt

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Posted 05 October 2022 - 09:29 AM

Yesterday was my day off, so it was case lining day. 

 

24" X 48" X 2 1/4" Kaizen foam from Home Depot. Cheapest I found anywhere for $38.

 

I turned this...

 

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Into this...

 

6f106c_29dffe651e9749f585299b5c785f3549~

 

I was a bit rushed in the afternoon when I was doing the EP tray, so I kind of butchered it. Great foam though...far superior to that soft, mushy pluck foam...

 

6f106c_4a1c5105364743b79e8a6c6f2dedbf33~


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#11 DSOGabe

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Posted 05 October 2022 - 04:08 PM

I've cut Kaizen foam before. It cuts pretty clean with a serrated steak knife too!

Or a fine toothed hacksaw blade!


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#12 havasman

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Posted 05 October 2022 - 04:43 PM

Or a fine toothed hacksaw blade!

The best for long straight cuts. Steak knife for more intricate shapes.

Source - FastCap  https://www.fastcap....uct/kaizen-foam

Recommend you buy in bulk 'cause if you have it, you will find good uses for it. Also the white core, black or dark blue surface foams make it really easy to replace pieces in the dark of night because the cutouts show really well in low light.


Edited by havasman, 05 October 2022 - 04:45 PM.

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#13 MarkMittlesteadt

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Posted 10 October 2022 - 10:37 AM

The best for long straight cuts. Steak knife for more intricate shapes.

Source - FastCap  https://www.fastcap....uct/kaizen-foam

Recommend you buy in bulk 'cause if you have it, you will find good uses for it. Also the white core, black or dark blue surface foams make it really easy to replace pieces in the dark of night because the cutouts show really well in low light.

Home Depot's 24" X 48" X 2/25" is $18 cheaper and they stock it in store (or free shipping to your local Home Depot).

 

I have so much leftover for other small cases. 


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#14 MarkMittlesteadt

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Posted 10 October 2022 - 10:43 AM

In looking at and using my new Kaizen foam lined AT72ED-II case (an Ace Hardware toolbox with a removable tray for EP's), it dawned on me that I can get rid of the tray and use something else to store my EP's around my scope...without altering the main scope layer in anyway.

 

Those black foam pipe insulation tubes are made of Kaizen Foam and come in different sizes (for different size pipes, or in my case, different sized EP's). I can cut them to length to suit the EP they will hold, and hot glue them together and all along the toolbox sides (utilizing the space around the OTA). The EP's will sit in the case vertically in this case. Because the handle is on top, the toolbox is never tilted sideways. 

 

Pics to come. wink.gif

 

Here's how I've used them in the past with my old Lunt 102ED and my own DIY wooden case. These all used the small tube foam, so they are split, but large foam tubing doesn't need to be split. NOTE...these foam tubes also make great finderscope sliding dew shields!

 

6f106c_f67b497de3c649849cda8077886250fa~


Edited by MarkMittlesteadt, 10 October 2022 - 11:17 AM.

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#15 MarkMittlesteadt

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Posted 10 October 2022 - 03:17 PM

It may not be "branded" Kaizen foam, but insulating pipe foam is made of the exact same closed cell foam. I went home over lunch and cut one of my pipe foam tubes down to fit my EP's. These will be hot glued together and then hot glued to the side of the case. The bottom of the EP's will rest on the top layer surrounding my scope and sit vertically in the lower part of my case (toolbox) eliminating the need for the upper tray. 

 

They are thick enough that I can shave off a little of the backside of each EP "tube" so they lay flat against the side of the toolbox where they'll be hot glued to each other and the case. This will easily hold all five of my EP's and my 2X and 3X Barlows. 

 

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Edited by MarkMittlesteadt, 10 October 2022 - 03:18 PM.


#16 doctordub

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Posted 10 October 2022 - 04:58 PM

I get my Kaizen Foam from Home Depot as well, and I use a Pumpkin Masters Electric carving saw.

 

https://www.walmart....g-Tool/17404484

 

CS

Jonathan

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  • Pumpkin carver.jpeg

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#17 MarkMittlesteadt

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Posted 11 October 2022 - 12:57 PM

I wonder how well a Dremel with a rotary cutting bit would work (the kind that cut perpendicular to the spin, like a router does). 


Edited by MarkMittlesteadt, 11 October 2022 - 12:58 PM.

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#18 fishonkevin

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Posted 11 October 2022 - 07:36 PM

I get my Kaizen from Rockler( https://www.rockler....BSABEgIdw_D_BwE ) . I don't think you can beat the 3-sheet deal. Here is my latest project.

 

Case 1
Album: APM 140 Case
5 images
0 comments

 


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#19 MarkMittlesteadt

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Posted 12 October 2022 - 10:04 AM

I decided to use some of my leftover Kaizen foam sheeting and made a solid foam block EP rack in my case. In the lower left (between my RACI finder and the scope diagonal) I have my 8-24 zoom EP. In my new foam EP rack (in the back right, up high) I have (left to right) my 2X Shorty Barlow, 9mm WA, 18mm WA, 25mm WA, and my 40mm UWA (top also threaded for afocal, to fit my DSLR).

 

The Kaizen foam is rigid yet provides protective cushioning. It's perfect for creating different levels and layers for a custom fit. I would never be able to do this with soft, mushy pluck foam. The foam EP rack is solid enough on its own, but it's also hot-glued to the case walls and the foam below it.

 

6f106c_0824262ac39d45059f55f07ec30b1a1d~

 

6f106c_0e3f5339cbde4d18b6fb83d3e49a8c96~


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