Custom foam insert for EP case

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Bigzmey United States of America
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Custom foam insert for EP case

#1

Post by Bigzmey »


This little Orion was my first EP case.
Orion_case-A.jpg
The pre-cut insert however was only designed for small 1.25" EPs, and some rectangular blocks? :lol:
Orion_case-B.jpg
Thus, fitting modern EPs is a challenge.
Orion_case-C.jpg
I look hard, but could not find any cubed foam insert of the right size. Besides, cubed foam is typically too soft to hold heavier EPs; and cubes fray with time. It was about time to learn how to make my own custom inserts.

I like to store EPs standing and needed a way to cut smooth circles of various sizes. I have considered hot wire foam cutters, hole saws, electric knives. Then, stumbled by chance on Youtube video of a guy using copper couplings - brilliant!

I bought a few 1" polyethylene foam sheets of eBay to cut to the size and stuck to desired depth (2" for this case). I went with polyethylene because it does not absorb moisture and resists compacting better than polyurethane.

Surprisingly, local hardware stores don't carry copper couplings larger then 1". eBay to the rescue again! These three sizes cover most of my EP collection except a few large EPs. I sharpen one side of each coupling and tested them on a foam piece. Basically, you apply a bit of pressure with your hand and twist it as you go. Works like a charm! Nice professional holes.
Orion_tools.jpg
Next step - design the layout (I use PowerPoint)
Orion_case layout.jpg
and start cutting
Orion_cutting.jpg
Final product!
Orion_case-D.jpg
Orion_case-E.jpg
Very happy how it turned out.
Scopes: Stellarvue: SV102ED; Celestron: 9.25" EdgeHD, 8" SCT, 150ST, Onyx 80ED; iOptron: Hankmeister 6" Mak; SW: 7" Mak; Meade: 80ST.
Mounts: SW: SkyTee2, AzGTi; iOptron: AZMP; ES: Twilight I; Bresser: EXOS2; UA: MicroStar.
Binos: APM: 100-90 APO; Canon: IS 15x50; Orion: Binoviewer, LG II 15x70, WV 10x50, Nikon: AE 16x50, 10x50, 8x40.
EPs: Pentax: XWs & XFs; TeleVue: Delites, Panoptic & Plossls; ES: 68, 62; Vixen: SLVs; Baader: BCOs, Aspherics, Mark IV.
Diagonals: Baader: BBHS mirror, Zeiss Spec T2 prism, Clicklock dielectric; TeleVue: Evebrite dielectric; AltairAstro: 2" prism.
Filters: Lumicon: DeepSky, UHC, OIII, H-beta; Baader: Moon & SkyGlow, Contrast Booster, UHC-S, 6-color set; Astronomik: UHC.
Solar: HA: Lunt 50mm single stack, W/L: Meade Herschel wedge.

Observing: DSOs: 3106 (Completed: Messier, Herschel 1, 2, 3. In progress: H2,500: 2180, S110: 77). Doubles: 2437, Comets: 34, Asteroids: 257
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Re: Custom foam insert for EP case

#2

Post by Don Quixote »


This is an awesome post Andrey !
Thank you very much.
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Re: Custom foam insert for EP case

#3

Post by Lady Fraktor »


A nice job Bigzmy, forstner bits work well on this type of foam also.
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See Far Sticks: Elita 103/1575, AOM FLT 105/1000, Bresser 127/1200 BV, Nočný stopár 152/1200, Vyrobené doma 70/700, Stellarvue NHNG DX 80/552, TAL RS 100/1000, Vixen SD115s/885
EQ: TAL MT-1, Vixen SXP, SXP2, AXJ, AXD
Az/Alt: AYO Digi II, Stellarvue M2C, Argo Navis encoders on both
Tripods: Berlebach Planet (2), Uni 28 Astro, Report 372, TAL factory maple, Vixen ASG-CB90, Vixen AXD-TR102
Diagonals: Astro-Physics, Baader Amici, Baader Herschel, iStar Blue, Stellarvue DX, Tak prism, TAL, Vixen
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Re: Custom foam insert for EP case

#4

Post by ARock »


Looks great Andrey !! Excellent idea on the couplings.

Can you post links on where you bought the polyethelene foam and the couplings from?
And also to the youtube video? My EP case pluck foam is starting to deform :)
AR
Scopes: Zhumell Z8, Meade Adventure 80mm, Bushnell 1300x100 Goto Mak.
Mount: ES EXOS Nano EQ Mount, DIY Arduino+Stepper drives.
AP: 50mm guidescope, AR0130 based guidecam, Canon T3i, UHC filter.
EPs: ES82 18,11,6.7mm, Zhumell 30,9mm FJ Ortho 9mm, assorted plossls, Meade 2x S-F Barlow, DGM NPB filter.
Binos: Celestron Skymaster 15x70 (Albott tripod/monopod), Nikon Naturalist 7x35.
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Re: Custom foam insert for EP case

#5

Post by bladekeeper »


Nice solution, Andrew!
Bryan
Scopes: Apertura AD12 f/5; Celestron C6-R f/8; ES AR127 f/6.4; Stellarvue SV102T f/7; iOptron MC90 f/13.3; Orion ST80A f/5; ES ED80 f/6; Celestron Premium 80 f/11.4; Celestron C80 f/11.4; Unitron Model 142 f/16; Meade NG60 f/10
Mounts: Celestron AVX; Bresser EXOS-2; ES Twilight I; ES Twilight II; iOptron Cube-G; AZ3/wood tripod; Vixen Polaris
Binoculars: Pentax PCF WP II 10×50, Bresser Corvette 10×50, Bresser Hunter 16×50 and 8×40, Garrett Gemini 12×60 LW, Gordon 10×50, Apogee 20×100

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Re: Custom foam insert for EP case

#6

Post by Bigzmey »


Lady Fraktor wrote: Tue May 28, 2019 1:01 am A nice job Bigzmy, forstner bits work well on this type of foam also.
Good to know! Thanks Gabby!
Scopes: Stellarvue: SV102ED; Celestron: 9.25" EdgeHD, 8" SCT, 150ST, Onyx 80ED; iOptron: Hankmeister 6" Mak; SW: 7" Mak; Meade: 80ST.
Mounts: SW: SkyTee2, AzGTi; iOptron: AZMP; ES: Twilight I; Bresser: EXOS2; UA: MicroStar.
Binos: APM: 100-90 APO; Canon: IS 15x50; Orion: Binoviewer, LG II 15x70, WV 10x50, Nikon: AE 16x50, 10x50, 8x40.
EPs: Pentax: XWs & XFs; TeleVue: Delites, Panoptic & Plossls; ES: 68, 62; Vixen: SLVs; Baader: BCOs, Aspherics, Mark IV.
Diagonals: Baader: BBHS mirror, Zeiss Spec T2 prism, Clicklock dielectric; TeleVue: Evebrite dielectric; AltairAstro: 2" prism.
Filters: Lumicon: DeepSky, UHC, OIII, H-beta; Baader: Moon & SkyGlow, Contrast Booster, UHC-S, 6-color set; Astronomik: UHC.
Solar: HA: Lunt 50mm single stack, W/L: Meade Herschel wedge.

Observing: DSOs: 3106 (Completed: Messier, Herschel 1, 2, 3. In progress: H2,500: 2180, S110: 77). Doubles: 2437, Comets: 34, Asteroids: 257
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Re: Custom foam insert for EP case

#7

Post by Bigzmey »


ARock wrote: Tue May 28, 2019 1:41 am Looks great Andrey !! Excellent idea on the couplings.

Can you post links on where you bought the polyethelene foam and the couplings from?
And also to the youtube video? My EP case pluck foam is starting to deform :)
Thanks AR!

Here is the foam link. They have other sizes as well
https://www.ebay.com/itm/2-pack-1-x-18- ... 2749.l2649

and couplings links
https://www.ebay.com/itm/Copper-Fitting ... 2749.l2649

https://www.ebay.com/itm/Discount-HVAC- ... 2749.l2649

The 3d size listing is no longer there but you can search for - 1-5/8" ID 1-3/4" OD Copper Coupling

Sorry, I did not save youtube link. I googled "cutting round holes in foam" and the video popped in search results.
Last edited by Bigzmey on Tue May 28, 2019 11:59 pm, edited 1 time in total.
Scopes: Stellarvue: SV102ED; Celestron: 9.25" EdgeHD, 8" SCT, 150ST, Onyx 80ED; iOptron: Hankmeister 6" Mak; SW: 7" Mak; Meade: 80ST.
Mounts: SW: SkyTee2, AzGTi; iOptron: AZMP; ES: Twilight I; Bresser: EXOS2; UA: MicroStar.
Binos: APM: 100-90 APO; Canon: IS 15x50; Orion: Binoviewer, LG II 15x70, WV 10x50, Nikon: AE 16x50, 10x50, 8x40.
EPs: Pentax: XWs & XFs; TeleVue: Delites, Panoptic & Plossls; ES: 68, 62; Vixen: SLVs; Baader: BCOs, Aspherics, Mark IV.
Diagonals: Baader: BBHS mirror, Zeiss Spec T2 prism, Clicklock dielectric; TeleVue: Evebrite dielectric; AltairAstro: 2" prism.
Filters: Lumicon: DeepSky, UHC, OIII, H-beta; Baader: Moon & SkyGlow, Contrast Booster, UHC-S, 6-color set; Astronomik: UHC.
Solar: HA: Lunt 50mm single stack, W/L: Meade Herschel wedge.

Observing: DSOs: 3106 (Completed: Messier, Herschel 1, 2, 3. In progress: H2,500: 2180, S110: 77). Doubles: 2437, Comets: 34, Asteroids: 257
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Re: Custom foam insert for EP case

#8

Post by Bigzmey »


As I mentioned the 3 coupling sizes I have used cover most of 1.25" EPs.

For the glass grenades I just ordered 2-1/2". I will let you know how it goes.

https://www.ebay.com/itm/Elkhart-2-1-2- ... 2749.l2649

So astronomy got me in to collecting copper couplings. :lol:
Scopes: Stellarvue: SV102ED; Celestron: 9.25" EdgeHD, 8" SCT, 150ST, Onyx 80ED; iOptron: Hankmeister 6" Mak; SW: 7" Mak; Meade: 80ST.
Mounts: SW: SkyTee2, AzGTi; iOptron: AZMP; ES: Twilight I; Bresser: EXOS2; UA: MicroStar.
Binos: APM: 100-90 APO; Canon: IS 15x50; Orion: Binoviewer, LG II 15x70, WV 10x50, Nikon: AE 16x50, 10x50, 8x40.
EPs: Pentax: XWs & XFs; TeleVue: Delites, Panoptic & Plossls; ES: 68, 62; Vixen: SLVs; Baader: BCOs, Aspherics, Mark IV.
Diagonals: Baader: BBHS mirror, Zeiss Spec T2 prism, Clicklock dielectric; TeleVue: Evebrite dielectric; AltairAstro: 2" prism.
Filters: Lumicon: DeepSky, UHC, OIII, H-beta; Baader: Moon & SkyGlow, Contrast Booster, UHC-S, 6-color set; Astronomik: UHC.
Solar: HA: Lunt 50mm single stack, W/L: Meade Herschel wedge.

Observing: DSOs: 3106 (Completed: Messier, Herschel 1, 2, 3. In progress: H2,500: 2180, S110: 77). Doubles: 2437, Comets: 34, Asteroids: 257
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Re: Custom foam insert for EP case

#9

Post by ARock »


Thanks Andrey !

I think this is the youtube link

AR
Scopes: Zhumell Z8, Meade Adventure 80mm, Bushnell 1300x100 Goto Mak.
Mount: ES EXOS Nano EQ Mount, DIY Arduino+Stepper drives.
AP: 50mm guidescope, AR0130 based guidecam, Canon T3i, UHC filter.
EPs: ES82 18,11,6.7mm, Zhumell 30,9mm FJ Ortho 9mm, assorted plossls, Meade 2x S-F Barlow, DGM NPB filter.
Binos: Celestron Skymaster 15x70 (Albott tripod/monopod), Nikon Naturalist 7x35.
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Re: Custom foam insert for EP case

#10

Post by Bigzmey »


ARock wrote: Wed May 29, 2019 12:12 am Thanks Andrey !

I think this is the youtube link

Yep!
Scopes: Stellarvue: SV102ED; Celestron: 9.25" EdgeHD, 8" SCT, 150ST, Onyx 80ED; iOptron: Hankmeister 6" Mak; SW: 7" Mak; Meade: 80ST.
Mounts: SW: SkyTee2, AzGTi; iOptron: AZMP; ES: Twilight I; Bresser: EXOS2; UA: MicroStar.
Binos: APM: 100-90 APO; Canon: IS 15x50; Orion: Binoviewer, LG II 15x70, WV 10x50, Nikon: AE 16x50, 10x50, 8x40.
EPs: Pentax: XWs & XFs; TeleVue: Delites, Panoptic & Plossls; ES: 68, 62; Vixen: SLVs; Baader: BCOs, Aspherics, Mark IV.
Diagonals: Baader: BBHS mirror, Zeiss Spec T2 prism, Clicklock dielectric; TeleVue: Evebrite dielectric; AltairAstro: 2" prism.
Filters: Lumicon: DeepSky, UHC, OIII, H-beta; Baader: Moon & SkyGlow, Contrast Booster, UHC-S, 6-color set; Astronomik: UHC.
Solar: HA: Lunt 50mm single stack, W/L: Meade Herschel wedge.

Observing: DSOs: 3106 (Completed: Messier, Herschel 1, 2, 3. In progress: H2,500: 2180, S110: 77). Doubles: 2437, Comets: 34, Asteroids: 257
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Re: Custom foam insert for EP case

#11

Post by mcolbert »


Bigzmey another thanks for an excellent thread! I will be sure to follow this up for my EP's. (The ones not already in a box that is). ;)
Refractor - APQ 130 Reflector - Meade SCT Au coating. Mount - AYOMaster (on order)
Cameras - Blads, D70s, D3300, Lunar and Planetary Cameras (2)
DIY Glass - German military and opthalmic sourced items, AGFA AVIPHOT DIA C
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