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Strawberry Orange Banana Lime Leaf Slate Sky Blueberry Grape Watermelon Chocolate Marble
Strawberry Orange Banana Lime Leaf Slate Sky Blueberry Grape Watermelon Chocolate Marble

The Patriot Woodworkers with Operation Ward 57 Adopt a Wounded Warrior Family for the Holidays - 2019 project is live, please click on link to view our very special annual project.

The Gun Case Final



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


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Great work, the Kaizan foam is a great product I use it for the custom cases for my Planes and drills and impact drivers. There are many different handles available at stores like Rockler and Woodcrafters but your work is outstanding.

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Can't wait to see the guns in the case Lew, that is going to look awesome. I agree with awardsr1, we used that foam for the Easy Wood Tools box and it works really nice. You put a lot of work into this project my friend, I am so happy it finally came to a great finish, you had a couple bumps on the way but you got em worked out. Great job Lew!

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2 hours ago, Gerald said:

This is a great looking piece. Love using the foam and have it in several shop drawers from planes to small items.

Thanks, Gerald!


Recently talked to the guy it was made for and he still has not completed the finish!

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