Zero Halliburton Case Restoration: Foam Cutting

ic-racer · Jun 4, 2024

I got this Zero Halliburton aluminum case in 1985 and have replaced the foam 3 times. Last time I went to use it the foam had fallen apart.
The last three times I used a long knife to cut the foam. It never came out too well.

This time I thought I'd try to cut the foam with a hot wire.

I got the replacement foam from www.cobrafoaminserts.com. They sell exact replacement for the four original pieces of foam that came in the case when it was new. The foam was a perfect fit.

ic-racer · Jun 4, 2024

Test fitting the equipment on the new foam.

ic-racer · Jun 4, 2024

This is the setup. A power supply and guitar string stretched tight. The little ViceGrip holds the wire tight. Below the guitar wire is looped around a wooden dowel with a wood screw holding the power wire and the guitar string tight together.
The two one-inch boxes are needed because the wire does not cut at the end, only near the middle (because the end cools at the attatchemnt point).

Trial and error was needed on the power supply (5 to 9 v depending on the wire). Hot enough to cut, but not so hot to become red (otherwise the wire breaks).

I tried a .010", 0.012" and 0.016" wire. (E, B and G). The 0.012" worked best for me.

ic-racer · Jun 4, 2024

I thought it came out pretty nice.

BrianShaw · Jun 4, 2024

Very nice; very clean!

DREW WILEY · Jun 4, 2024

Foam cutting is done with a wavy sharp edged steel blade that resembles a bread knife. There are special power cutters which do this, employing very narrow knives which can make tight turns. These machines are generally expensive, although cheaper amateur version can be found online. But I've also sold wavy blades which fit regular handheld electric jigsaws. Hot wires and hot knives are not generally used for spongy foam, just firm styrofoam.

Glad you found your own solution. The bigger problem is how to keep shiny Halliburton cases from being stolen!

ic-racer · Jun 4, 2024

The center two pices of foam are pretty dense, Shore A of 40 or so, just as I remember the original. More dense than the squishy top and bottom pieces and more dense than typical segmented pluck' foam. So, this was almost like cutting styrofoam.

GRHazelton · Jun 4, 2024

I've used an electric knife with two moving serrated blades. Intended for food use - it does well on turkey breasts and freshly baked bread - it does well on plastic foam, although sharp "turns" are...difficult.

MTGseattle · Jun 4, 2024

Definitely cleaner than the Pelican "pick-apart" style foam.

DREW WILEY · Jun 5, 2024

Ha! I was given a test sample of a big wavy foam knife designed to fit a construction reciprocal saw or Sawzall. It was too long, thin, and floppy. The manufacturer almost immediately gave up on the idea of marketing it. But for fun they took one of these, along with the electric saw, to their own company Christmas party. It actually worked quite well carving up the turkey. This was before commercialized electrical meat carving and bread knives started showing up at kitchen stores.

MarkS · Jun 5, 2024

Calumet used to sell Cordura covers for Halliburton cases; the idea was that you would cover them with paint splotches and graffiti to hide the shiny aluminum, and deter potential thieves.
Most all of them that I've seen had decaying foam, and I never knew how to replace it. So I've never considered using one- but they sure are elegant.

DREW WILEY · Jun 5, 2024

If any moisture gets inside, open-cell foam starts going powdery. My older brother had a commercial photography career when it was deemed appropriate to look successful. He wore white shoes, drove a Porsche, and used shiny Halliburton cases. His gear was repeatedly stolen. So then he put a big sticker on his cases, "Dead Cat Enclosed". That didn't work.

mshchem · Jun 5, 2024

ic-racer said:
I thought it came out pretty nice.

View attachment 371518 View attachment 371519

That looks great, very cool. NASA used these cases to bring back moon rocks.

eli griggs · Jun 5, 2024

DREW WILEY said:
Foam cutting is done with a wavy sharp edged steel blade that resembles a bread knife. There are special power cutters which do this, employing very narrow knives which can make tight turns. These machines are generally expensive, although cheaper amateur version can be found online. But I've also sold wavy blades which fit regular handheld electric jigsaws. Hot wires and hot knives are not generally used for spongy foam, just firm styrofoam.

Glad you found your own solution. The bigger problem is how to keep shiny Halliburton cases from being stolen!

I bought some nice foam for camera case use and was advised, here I think, to use an electric carving knife, which was not expensive on Amazon, a Sunbeam, with narrow blades IIRC.

It cuts foam well and shapes well so take a look on what's on line.

ic-racer · Jun 5, 2024

Yes, electric meat carving knife works too. I used one on the little rectangular openings (evident by no burn marks). But I find it harder to make a perpendicular cut, or, as pointed out, a curved cut.

Beevo · Mar 7, 2025

Here is how I make round holes:

Here is the build info on the cutter:

Foam Hole Saw

ic-racer · Mar 7, 2025

How are you making rectangular or free-form cuts in that foam?

Beevo · Mar 7, 2025

If the pieces to cut are smaller than 10x10 inches I put them in my laser engraver. These pages outline the laser process:

Small tool Storage

Pentax110 Super SLR

In the past i have used a bread knife. I have not gotten to the rectangular holes yet and the case inserts I am now making are way too big to fit in the laser. I have an electric carving knife coming tomorrow...

Pieter12 · Mar 7, 2025

I have yet to try them but if I were to need a custom hard shell case insert, this looks intriguing: https://mycasebuilder.com/?gad_sour...DxlddLPVzlIho2tUQtvNfsEqZguTObaYaAoErEALw_wcB

Beevo · Mar 7, 2025

I wonder on the cost though...

Pieter12 · Mar 7, 2025

Their precut inserts should give you an idea for a variety of sizes. https://mycasebuilder.com/i-need-a-case-foam/pre-made-designs/camera-video/

Beevo · Mar 9, 2025

Beevo said:
In the past i have used a bread knife. I have not gotten to the rectangular holes yet and the case inserts I am now making are way too big to fit in the laser. I have an electric carving knife coming tomorrow...

The carving knife works very well. I have it cleaned up and ready to carve the home corned beef we are having for dinner tonight. (twofer)

Here are the results of my case for the Pentax 6X7: https://www.beevo.org/Photography/PhotographicEquipment/Pentaximus/index.htm

The page about the hole saw has been updated: http://www.beevo.org/Photography/PhotographicEquipment/FoamHoleSaw/FoamHoleSaw.html

r_a_feldman · Mar 9, 2025

I find that a snap-blade razor knife (the OLFA-5023-Multi-Purpose-Craft-Knife is one example) works well enough for me. I just extend the blade out and carefully cut with a sawing action.

Beevo · Mar 9, 2025

These sheets were 2" thick and fairly stiff foam. I have used the grown up version of the Olfa knife in the past.

Don_ih · Mar 10, 2025

I'd use a scroll saw to cut such foam, with a multi-direction blade. But I have a scroll saw.

Zero Halliburton Case Restoration: Foam Cutting

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