Re: FS: UK Stick #1642 Original with hard case)
DavidWS wrote:
mahabresq wrote:
or cover the cut foam with some material.
Thanks for the tips eveyone. Approximate cut, then cover with fabric is probably the way I'd go.
I'm not sure how much this will help you in the UK, David, but I've been researching this, as I was thinking of making a hard case for my Railboard when it comes in. Maybe the info below can help you to find something suitable on your side of the pond.
What I think you want is
polyethylene foam. You may have seen this in some packaging. It looks a bit like styrofoam, but is very flexible and very tough. Unfortunately it's expensive. I've found some sellers that offer sheets suitable for Sticks that are made for long-gun cases (shotguns or hunting rifles). The ones I've found run about $65 US for a hunk big enough for a Stick case, 4" thick:
https://www.amazon.com/dp/B015JRXH1W/ref=cm_sw_em_r_mt_dp_AX439QR8CZJW2JPJR564?_encoding=UTF8&psc=1However, I note that many cases (maybe even the hardshell cases from SE) do not completely enclose the instrument, instead having a block at each end with a recess for the headstock and the pickup block, and a narrow third block in the middle. No need to have to fill the entire case, and leaving some empty spaces allows for stowage of extra pieces of kit. That said, I agree that covering even polyethylene foam with fabric is a nice touch.
It doesn't save a ton of money, but here is a listing for smaller chunks of polyethylene foam. Note the picture at the left showing the spring clamp and how rigid this foam is. This particular listing includes 10" x 8" x 2" blocks for $13 US each, so four of them (which would be needed for the case I have here, 7" wide inside and a 4" depth) would come to about $52. If I cut them to provide 10" of support at each end and cutting them down to the 7" width would give me 4 pieces 1" x 10" x 2" which could be glued together to form a center support. I could also get away with using the 8" length which would fully support the headstock and butt end, though not entirely under the pickup block, but would also give me 4 pieces 8" x 3" x 2" high which would give me a more robust center support.
https://www.amazon.com/dp/B08ZJYWNBQ/ref=cm_sw_em_r_mt_dp_RBASDHXMS02ZXJ37WRBS?_encoding=UTF8&psc=1One last thing. Cutting the outline isn't hard, especially with this very firm foam. It cuts like a dream. One of those thin utility knives with the snap-off scores, fully extended, using a straightedge, will make the vertical cuts to accommodate the instrument very neatly. The problem is getting the bottom of the cutout flat. A company called FastCap sells this foam as "Kaizen foam", and it's a bit cheaper. A 2' x 4' x 57mm (2 1/4") sheet is only $55 US per sheet. They also sell tools for cutting and shaping it, including a scraper for leveling the bottom of the cutout. Although in a pinch, I wouldn't be above hot-gluing a razor blade to the end of a popsicle stick to achieve the same thing.
Here is a link to the foam:
https://www.fastcap.com/product/kaizen-foamAnd here is the scraper ($11 US)
https://www.fastcap.com/product/kaizen-scraper