Introduction: Foam, Water Tight, Crush Proof Cases
Create a storage system for all of your sensitive camera, drone, or tool equipment. This project uses a 3 container system that is readily available from Home Depot. The containers are very strong and while I wouldn't guarantee the waterpfroofness of the containers, they do have a seal that would protect from rain or a quick dunk into a body of water. The inserts are available from the Foam Factory. Using the Charcoal Pick and Pluck foam in the sizes listed in the instructable, they are easily ordered from here: http://www.foambymail.com/charcoal-pick-and-pluck-...
Foam used in the project are:
For the top (small) case:
Small (12"x13") - in thicknesses 2", 1" and 1 1/2"
For the middle (medium) case:
Medium (18"x20") - in thicknesses 3", 2", 2", 1" and 1"
For the bottom (large) case:
Medium (18"x20") - thicknesses 3", 3*2", and 3*1"
I ordered the following foam:
One Small (12"x13") @ 2"
One Small (12"x13") @ 1 1/2"
One Small (12"x13") @ 1"
Two Medium (18"x20") @ 3"
Five Medium (18"x20") @ 2"
Seven Medium (18"x20") @1"
and ended up not using three of the medium sized 1" thickness foam. I liked having the extra though because it allows flexibility.
Step 1: Small Case
I used the small sized pieces of foam here. Two inch on the bottom, One and a half inch on top of that and then 1" tucked into the top. The 1" piece is held to the top using wide double sided tape.
I opted to keep the six cups available for other objects that could be loose. If you want though, you could get the medium sized pieces of foam (18"x20") and cover all of this case with foam.
Step 2: Medium Case W/ Tray & Lid Descriptions
I actually did this case last so that I could use remnants of foam from the other two cases to fill in the top and the tray.
In the tray and in front of it are two layers of 1" foam.
In the top, various sizes of foam were used. In the middle a 1" layer with some deeper cavities filled with another layer as needed. Where appropriate 2" thicknesses were used and in the four corners, four pieces of 3" thicknesses.
Note that the foam had to be plucked from the cover where the tray handle goes when the lid is closed.
Step 3: Medium Sized Case Layers
The bottom layer of this case begins with the 3" thick foam, then two layers each of 2" foam. On top of this last layer are added two layers of 1" foam for the tray and in front of the tray as described in another step.
Each layer for this case needs to have a variety of squares plucked so as to fit around different structures within the interior of the case. It's better to pluck a layer at a time and test fit as needed so as to get a good fit without having to place loose cubes back in.
Step 4: Bottom Case Layers
The layers for the bottom case begin with a 3" layer on the bottom, then a 1" layer, then a 2" layer, alternating that way three times. Each layer has to have foam plucked from it so as to fit around protrusions in the interior of the case.
Step 5: Lid of the Bottom Case
The layers of the bottom will end just shy (1/2") ot the top but by packing the lid with a variety of thicknesses of foam sized to fit the cavities, the foam can be made to protrude from the top so that when the top is seated, the whole cavity will be filled with foam as shown in the pictures.
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