The final installment of this project is just a little follow-up on the last details. My friend supplied the hardware and liner for me to install.
The latches snap securely and installed easily, as did the hinges. The only caveat was that the sides of the case were 1/2" thick and the screws were a little longer. The difference isn't noticeable due to the type of liner he chose. The short protruding nibs actually help keep the foam in place.
I had never worked with this material. There are a few videos on the Internet explaining how to cut and shape it to your needs. Because I was placing it inside a box and the fit needed to be perfect, I cut the foam to size on my table saw using a fine toothed blade from my circular saw. Worked Perfectly!!
I was able to get both the lid and bottom liner from a single sheet of 58mm material. The box bottom used the piece's full thickness. The lid, however, needed the material to be a little less than 1" thick. The plan was to simply separate the 58mm foam into a thinner sheet.
The foam is manufactured in layers. The concept is to cut out an outline of the item you want to store and then remove the foam layers to create a cavity. My thoughts were- "Hey, I'll use the same idea and just thin down the thick piece." Not so fast, pilgrim! Let's just say it sounded easier than it turned out. The surface where the material separated is extremely rough. Fortunately, that surface is not seen.
He still hasn't decided on a carrying handle. He is thinking of something like a woven becket-
My friend comes from a family of "finishers", so I think that part of the project will be handled by them.
Well, that's it! Thanks for reading along