This looks like genius
Any chance you could do step by step instructions, please
@Wade Cornell ?
I would like to know how you control the foam to create a level surface in each half of the case because in my experience with the foam in cans it expands, then expands, then expands
Also how deep does the sax sit in the bottom half of the case? Does the sax sink like a stone, do you have to suspend it, does the sax sit proud of the lower half at all? If the sax pokes into the upper half of the case how do you manage the foam in the upper half? Etc.
All good questions. You've got to be able to visualize where you're going to see your way through.
1. The sax is thoroughly wrapped in cling film.
2. The sax is placed on top of foam blocks (old packing material, Styrofoam etc.) in the position you want. Have it positioned so that it will be half way in the foam when the case is opened. This means that when the top half is closed it is encased.
3. Blow foam under and around the horn so that it extends just past the lip level of the case. This is tricky as you've got to have a feel for how much the foam expands, but can do just a little at a time. The horn may need to be held down if it's a small horn to ensure it's not lifted off your blocks.
4. let the foam set to hard.
5. Remove the horn. If bits of foam have gone over that half way point you may need to use a Stanley Knife to cut it free (carefully). It doesn't matter if some of the cling film gets damaged as you can re-wrap it.
6. Cut and sand off the foam so that it is level or just slightly below the lip of the case.
7. Re-wrap the horn in cling film.
8. This is a tricky part: put the horn back into the bottom half that you just finished and cut blocks of foam that are temporarily glued to the top half of the case. The lid of the case MUST be able to close easily, and the horn MUST NOT rattle/move in the case. This will take a bit of adjustment.
9. Open the case upside down and make sure that the horn has NOT moved position when sitting in the top half, If it has repeat # 8 until you have it right.
10. Blow foam repeating steps 3 to 6 for the top half.
11. Remove cling film from horn and anywhere stuck in the foam. Put the horn back in the case and ensure that the case closes and you have a good fit. Adjust with Stanley Knife and sand paper if too tight.
12. Purchase enough of a very 2-way stretchy fabric for lining both sides of the case. Lay one bit over the bottom half (loosely) and place the horn in the case. Place the other bit over the horn and see if you can close the case. Adjust the foam until the case closes.
13. Cut the fabric to fit with enough slack to ensure that the horn can rest on the bottom of the foam and is NOT held up by the fabric.
14. Using contact cement coat the foam and lightly brush on the glue to the fabric (don't soak it).
15. Press into place attaching the outside of the fabric to the case edge first, then pushing into the deepest parts of your form. This may need to be done "upside down" to ensure that other areas don't touch and stick first.
16. You should have a perfectly molded case. If it's too tight try to identify what area is high and use a hammer and tools that are NOT sharp to punch/push the foam down until a perfect fit.
If you can picture all of the above it's not as difficult as it sounds.
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