Injection Molding

[Tree Reaper]

Got this one finished.

[TZHunter]

Hey, how did you plug the holes ? My mind is thinking....squirt a bunch of foam, then pull the can out, and stick something in there REALLY fast before the foam expands and comes out the hole. . . . for those from that generation, couldn't you just imagine Lucy (I Love Lucy) trying to do this and all the foam coming out everywhere ?

Anyway, would appreciate hearing how you managed to get the holes plugged before the foam came out and how you plugged. Thanks, TZHunter

[Tree Reaper]

I drilled the two holes, one for foam and the other for the air to escape.

The holes are the exact same size as the straw you get with the foam.

From the outside of the form I counter bored the two holes out about one inch in, one size under 1/4" to match two dowel plugs that I cut with tapered ends.

When the foam starts to exit the holes, drive in the plugs, cut them flush and put the mold into a wood working vise.

[WinterBear]

Ok, the lighter case is great, I love the idea, and it looks like it really made a strong case. I see some similar sharpie holsters in my future as soon as my friend sees this.

[DoubleC]

Hey, how did you plug the holes ? My mind is thinking....squirt a bunch of foam, then pull the can out, and stick something in there REALLY fast before the foam expands and comes out the hole. . . . for those from that generation, couldn't you just imagine Lucy (I Love Lucy) trying to do this and all the foam coming out everywhere ?

Anyway, would appreciate hearing how you managed to get the holes plugged before the foam came out and how you plugged. Thanks, TZHunter

I used the same analogy, with me being Lucile Ball :-)

[TZHunter]

When picturing this in my mind, I also recalled some of my failed attempts at plumbing repairs, when I didn't have a cut-off valve and thought I could just unscrew that little thing and screw it back on real quick even though water was gushing out with ridiculous force. Sure glad to hear others have success when doing things like this, it gives me hope one day I may too succeed. I must admit, this idea is genius ! I'm feeling confident enough to try it.

[DoubleC]

UH TZ? I did some plumbing, well I've done quite a bit and when I couldn't find the shut off valve, I had the water company turn the water off, LOL. Are you SURE you want to try this? Cheryl

[Tree Reaper]

It's important to cover all of the leather and more with light plastic to prevent the foam from sticking to the bottom of the wood mold because it's like glue and will adhere both sides of the mold together.

The foam doesn't stick to plastic.

[DoubleC]

Yeah TZ that? You don't want to glue yourself to a wood mold, or a shut off valve, LOL.

[amuckart]

What sort of light plastic do you use?

Thanks for sharing this technique.