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DIY Foam Packing
Jun 22, 2022 07:30:46   #
jerryc41 Loc: Catskill Mts of NY
 
I got the RC truck that I'm going to use to drive the GoPro around yesterday, and I want a box for it. I decided to use one of those $20 Plano 20.5" toolboxes. The truck arrived in a form-fitting plastic shell that will fit into the toolbox. What I plan to do is fill the other side of that shell with expanding foam. When it hardens, it will be a firm, properly-shaped support for the truck and the remote control.

I've seen something like this done with products I've received, and I'm sure you have, too. They shoot the expanding foam into a plastic bag and then press the product on top. I could also use the technique below, but I think that would be sloppier.

https://www.ehow.com/how_7405490_use-canned-foam-packaging.html

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Jun 23, 2022 05:44:08   #
Manglesphoto Loc: 70 miles south of St.Louis
 
jerryc41 wrote:
I got the RC truck that I'm going to use to drive the GoPro around yesterday, and I want a box for it. I decided to use one of those $20 Plano 20.5" toolboxes. The truck arrived in a form-fitting plastic shell that will fit into the toolbox. What I plan to do is fill the other side of that shell with expanding foam. When it hardens, it will be a firm, properly-shaped support for the truck and the remote control.

I've seen something like this done with products I've received, and I'm sure you have, too. They shoot the expanding foam into a plastic bag and then press the product on top. I could also use the technique below, but I think that would be sloppier.

https://www.ehow.com/how_7405490_use-canned-foam-packaging.html
I got the RC truck that I'm going to use to drive ... (show quote)


NO matter how you do it expanding foam is messy. Becareful of the expansion type you use or it could swell your tool box to where it won't close!!

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Jun 23, 2022 08:05:12   #
jerryc41 Loc: Catskill Mts of NY
 
Manglesphoto wrote:
NO matter how you do it expanding foam is messy. Becareful of the expansion type you use or it could swell your tool box to where it won't close!!


Yes, it can be a real mess. I'm going to do this outside. If it doesn't work, it doesn't work. I just like experimenting.

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Jun 23, 2022 09:11:20   #
DaleBrown
 
That’s a great idea
Good luck

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Jun 23, 2022 09:30:00   #
sr71 Loc: In Col. Juan Seguin Land
 
I shipped a completely built quad copter from Fayetteville, Nc to Seguin, Tx arrived in perfect shape. Son in Law stated that's how they shipped parts n stuff from the sand box.

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Jun 23, 2022 10:36:37   #
BebuLamar
 
So which truck did you get?

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Jun 23, 2022 14:28:58   #
jerryc41 Loc: Catskill Mts of NY
 
BebuLamar wrote:
So which truck did you get?


It was cheap, but it has proportional speed and steering. It was about $67 delivered, last week.
https://smile.amazon.com/gp/product/B07JM9LXCC/ref=ppx_yo_dt_b_asin_title_o04_s00?ie=UTF8&psc=1

My dog gets a kick out of it. I have to figure what kind of a camera mount to put on it. I'm not going to put all the snap-on extras on it.



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Jun 23, 2022 14:36:10   #
KillroyII Loc: Middle Georgia
 
jerryc41 wrote:
I got the RC truck that I'm going to use to drive the GoPro around yesterday, and I want a box for it. I decided to use one of those $20 Plano 20.5" toolboxes. The truck arrived in a form-fitting plastic shell that will fit into the toolbox. What I plan to do is fill the other side of that shell with expanding foam. When it hardens, it will be a firm, properly-shaped support for the truck and the remote control.

I've seen something like this done with products I've received, and I'm sure you have, too. They shoot the expanding foam into a plastic bag and then press the product on top. I could also use the technique below, but I think that would be sloppier.

https://www.ehow.com/how_7405490_use-canned-foam-packaging.html
I got the RC truck that I'm going to use to drive ... (show quote)


good feedback from Manglesphoto ... also you might consider (1) practice on something 1st & (2) in addition to shooting the foam in a plastic bag also wrap your car in separate plastic bag... just in case... you don't want to let an accident result in foam in parts of your new car

Years ago I was in and out of our companies shipping/receiving department and saw them using the foam... they bagged the item and shot foam in a baf in the box.

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Jun 23, 2022 14:41:52   #
jerryc41 Loc: Catskill Mts of NY
 
KillroyII wrote:
good feedback from Manglesphoto ... also you might consider (1) practice on something 1st & (2) in addition to shooting the foam in a plastic bag also wrap your car in separate plastic bag... just in case... you don't want to let an accident result in foam in parts of your new car

Years ago I was in and out of our companies shipping/receiving department and saw them using the foam... they bagged the item and shot foam in a baf in the box.


I didn't explain myself well enough. I am going to use the molded plastic that was holding the truck in the box as a mold. I'll turn it upside down and spray foam inside. It doesn't matter how much foam flows outside because I can trim it to fit into the box. The truck won't touch the foam until it is solidified. I'll have to spray Pam or something similar inside the plastic so the foam will release from it. I like the plastic bag idea, and I might try that with something else.

When I use the foam-in-the-bag, I will definitely wrap whatever it is in plastic, just in case the bag rips. I have some cans of foam arriving on Tuesday, but I have to go into town tomorrow, so I might buy some. I can always use foam.

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Jun 23, 2022 15:39:38   #
KillroyII Loc: Middle Georgia
 
jerryc41 wrote:
I didn't explain myself well enough. I am going to use the molded plastic that was holding the truck in the box as a mold. I'll turn it upside down and spray foam inside. It doesn't matter how much foam flows outside because I can trim it to fit into the box. The truck won't touch the foam until it is solidified. I'll have to spray Pam or something similar inside the plastic so the foam will release from it. I like the plastic bag idea, and I might try that with something else.

When I use the foam-in-the-bag, I will definitely wrap whatever it is in plastic, just in case the bag rips. I have some cans of foam arriving on Tuesday, but I have to go into town tomorrow, so I might buy some. I can always use foam.
I didn't explain myself well enough. I am going t... (show quote)


re read it--- you did explain, I just didn't let it sink in... good plan

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Jun 23, 2022 18:40:26   #
TheShoe Loc: Lacey, WA
 
You could also try the Flex Seal rubber products. If Phil Swift can make a bout out of the stuff, it would possibly be suitable for this application.

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Jun 24, 2022 11:30:04   #
Lonnie77 Loc: Kennedale, Texas
 
You may want to add a gimbal.

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Jun 24, 2022 13:47:00   #
PhotogHobbyist Loc: Bradford, PA
 
jerryc41 wrote:
I got the RC truck that I'm going to use to drive the GoPro around yesterday, and I want a box for it. I decided to use one of those $20 Plano 20.5" toolboxes. The truck arrived in a form-fitting plastic shell that will fit into the toolbox. What I plan to do is fill the other side of that shell with expanding foam. When it hardens, it will be a firm, properly-shaped support for the truck and the remote control.

I've seen something like this done with products I've received, and I'm sure you have, too. They shoot the expanding foam into a plastic bag and then press the product on top. I could also use the technique below, but I think that would be sloppier.

https://www.ehow.com/how_7405490_use-canned-foam-packaging.html
I got the RC truck that I'm going to use to drive ... (show quote)


How would it work if you fill the underside of the plastic shell with the foam, let it set then carefully cut, shave or sand the foam to even with the bottom of the shell allowing it to sit evenly on the bottom of the toolbox. Doing likewise with the shell that fits over the truck (if that exists) would provide more protection for the top of the truck.

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Jun 24, 2022 15:55:17   #
jerryc41 Loc: Catskill Mts of NY
 
PhotogHobbyist wrote:
How would it work if you fill the underside of the plastic shell with the foam, let it set then carefully cut, shave or sand the foam to even with the bottom of the shell allowing it to sit evenly on the bottom of the toolbox. Doing likewise with the shell that fits over the truck (if that exists) would provide more protection for the top of the truck.


Yes! That's exactly what I started doing a few hours ago. I think I made a mistake by adding all the foam at once. It's going to take too long to dry, and I have my doubts about how it will stick together. I'll leave it for a day ot more. Fortunately, I have another can of foam and the other half of that plastic shell.

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Jun 25, 2022 08:20:06   #
jerryc41 Loc: Catskill Mts of NY
 
Update - Here are some things to keep in mind if you want to do this yourself. I like experimenting, and I don't expect each attempt to be a success on the first try.

Using the foam without the original plastic shell would have been a disaster.

I used one half of the plastic shell, and I wrapped the truck in plastic-wrap. The plastic-wrap only made it worse. It made the truck bulkier and harder to fit into the plastic mold.

I put the truck into the mold, fearing that the expanding foam would distort the plastic mold and make it useless. Then I inserted it into the original box to keep the shape.

I waited maybe an hour to start looking inside the box because the top of the foam was hard. As I cut the box away, I saw that the foam was still soft inside, so I waited a few hours.

When I finally got it out of the box, the foam closest to the truck didn't go to the bottom of the mold in several places, so retaining the mold is possibly essential.

Trying to remove the mold from the foam would probably destroy the foam, the mold, or both. It's an intricate shape with lots of areas for it to grip.

I should have applied a small amount of foam and waited for it to set. Applying layer after layer should produce better results, but I think I would still need the plastic mold.

Mold or no mold? Although it would be nice to avoid using the mold for the final packing in the carry case, I doubt that the foam would produce a smooth enough base for the truck. With the mold, it's guaranteed to fit.

It took an entire can of foam to fill the mold, and that surprised me. The two cans I bought cost about $6.50, so it's not a huge expense.

I have another can of foam and the other half of the mold, so I might try again today.

As a side note, the Plano toll box that was supposed to arrive on Tuesday was delayed. Home Depot has the same box for the same $18+, but I would have to wait a week or more for it.









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