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Old 11-06-2005, 01:09 PM   #6
Autostream OP
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Joined: Aug 2005
Location: Croydon North, Victoria, Australia
Oddometer: 5,826
carving closed cell foam...

For the first couple of prototypes I used a very sharp hobby knife. This foam is sort of layered and you could just cut through about 5mm and peel a layer out.

For the version you see I used a butane powered soldering iron with a nylon rope cutting tip (a wedge shape) and simply melted the shape in with lots of patience.

For those that are not metricated 1" = 25.4mm, so there is about 4/5 of an inch space to play with...it does taper slightly with the front being a tad thicker than the rear area, but the foam is 20mm and fits (quite snug at the rear, seat takes a bit of a push to latch down)
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