Author Topic: Kaizen Foam!! How to customize it.  (Read 1916 times)

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Offline presidentsdad

  • Posts: 43
Kaizen Foam!! How to customize it.
« on: October 22, 2019, 02:51 PM »
Hello FOG!
I’ve had a number of questions regarding the Kaizen foam from FastCap.  To help me answer those questions, Hans at TSO Products sent me a kit with Kaizen Foam already cut for systainers (a 20mm and 30mm set of inserts), a long reach marker, a Kaizen knife, and a Kaizen Hot Knife.  THANKS Hans!!

Using it was fairly simple.  Arrange the items (sorry about the non Festool tools in the Festool systainer)  [eek]  on the Kaizen foam, trace with the long reach marker, determine the depth, trace the lines with the Kaizen knife, peel out the foam (a few layers at a time), test fit, cut or peel out more foam, test fit again, and use the hot knife and “penny” tip to flatten the bottom and the edge of the hot knife to make a thumb hole for the various small pieces.

Having said that, a couple of things.  For my application, the 30mm foam was not quite deep enough, so I used some 3M Super 77 to laminate to two pieces of Kaizen foam together.  This allowed me to go about 40mm deep and still have about 10mm for cushion on the bottom.  Make sure you hold the pen as straight up and down as you can, because if you don’t, you’ll be coming back to cut out more foam.  Keep the Kaizen knife as perpendicular to the surface as you can (or you might cut through the side).  The hot knife on the hottest setting needs a light touch to sculpt the bottom flat and to burn in the thumb holes. 

Overall fairly easy as I said.  I’d totally do it again and now I’m looking for more projects to do this with!

Again, thanks to HANS at TSO PRODUCTS!!


Below will be the pictures/explanation.  Let me know if you have any questions!
« Last Edit: October 23, 2019, 08:53 AM by presidentsdad »
PresidentsDad - TS75; FS1900; CT36; RO150

Offline presidentsdad

  • Posts: 43
Re: Kaizen Foam!! - How to Customize it.
« Reply #1 on: October 22, 2019, 03:02 PM »
305828-0 - Long reach marker, Kaizen Knife and Hot Knife
305830-1 - Items Laid Out
305832-2 - Tracing items
305834-3 - Determining Depth
305836-4 - Cutting (sorta) straight
305838-5 - Peeling foam
305840-6 - Laminating foam pieces together
305842-7 - All cut out
305844-8 - Pew Pew!!
305846-9 - Before shaping
305848-10 - After Shaping, don't press too hard
305850-11 - All done!
« Last Edit: October 23, 2019, 08:53 AM by presidentsdad »
PresidentsDad - TS75; FS1900; CT36; RO150

Offline jobsworth

  • Posts: 5895
  • Festool Baby.....
Re: Kaizen Foam!! How to customize it.
« Reply #2 on: October 23, 2019, 11:08 AM »
Thanks for the info. I didnt know they made a Kaizen Hot Knife.

The last day or 2 I was thinking about using a hot knife for a up coming project. Now I get the fast cap one.

Offline hdv

  • Posts: 75
Re: Kaizen Foam!! How to customize it.
« Reply #3 on: October 23, 2019, 11:50 AM »
For those interested in saving some money (that being said to the FOG audience...  [huh] ). As far as I can see that hot knife is a repackaged Walnut Hollow Creative Versa Tool that can be bought at half the price. I did buy the Walnut version about half a year ago and it works quite well.

See this page on Amazon

P.S. Heating foam can release nasty fumes, so I recommend wearing a respirator mask with the right cartridges when doing that.

Offline Michael Kellough

  • Posts: 4268
Re: Kaizen Foam!! How to customize it.
« Reply #4 on: October 23, 2019, 12:16 PM »
I can smell it now!

A hot wire cutter works pretty well on polystyrene foam because the foam shrinks when it gets to it’s melting point. Polyethylene foam (Kaizen foam) shrinks less. It moves more from gravity than it shrinks.

Use a long thin knife with a fast reciprocating motion for polyethylene foam.

Offline SRSemenza

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  • Posts: 8994
  • Finger Lakes Region, NY State , USA
Re: Kaizen Foam!! How to customize it.
« Reply #5 on: October 23, 2019, 02:42 PM »
For those interested in saving some money (that being said to the FOG audience...  [huh] ). As far as I can see that hot knife is a repackaged Walnut Hollow Creative Versa Tool that can be bought at half the price. I did buy the Walnut version about half a year ago and it works quite well.

See this page on Amazon

P.S. Heating foam can release nasty fumes, so I recommend wearing a respirator mask with the right cartridges when doing that.

Is that hot knife blade replaceable?  If so it looks like it will take any type of "exacto" blade.

Seth

Offline hdv

  • Posts: 75
Re: Kaizen Foam!! How to customize it.
« Reply #6 on: October 23, 2019, 05:21 PM »
Yes it is. See photo.



Offline Dusty.Tools

  • Posts: 154
    • Dusty.Tools
Re: Kaizen Foam!! How to customize it.
« Reply #8 on: October 25, 2019, 08:24 AM »
FYI, I just got an email from FastCap about a new Kaizen Foam scraping tool.

https://www.fastcap.com/product/kaizen-scraper?utm_source=FastCap&utm_campaign=e5d10874a9-FC-kaizen-foam-scraper-20191024&utm_medium=email&utm_term=0_8c1f8244f9-e5d10874a9-412194413
Thanks for the heads up! I’m going to give it a try.


Sent from my iPhone using Tapatalk
@dusty.tools

Offline Mike Goetzke

  • Posts: 373
Re: Kaizen Foam!! How to customize it.
« Reply #9 on: October 25, 2019, 09:11 AM »
This is impressive. Looks like sculpting Kaizen Foam could be a hobby on it's own (or is it an art form?).

Offline Cheese

  • Posts: 6542
Re: Kaizen Foam!! How to customize it.
« Reply #10 on: October 25, 2019, 10:45 AM »

Offline PeterJJames13

  • Posts: 195
Re: Kaizen Foam!! How to customize it.
« Reply #11 on: October 25, 2019, 10:49 AM »
@Cheese  I was thinking the Stanley Surform like a 21-515

Offline Cheese

  • Posts: 6542
Re: Kaizen Foam!! How to customize it.
« Reply #12 on: October 25, 2019, 10:55 AM »
@Cheese  I was thinking the Stanley Surform like a 21-515

Ya you're right...the Surform was the original Microplane.  [cool]  I still use the Surform occasionally, not very often but occasionally.

Offline PeterJJames13

  • Posts: 195
Re: Kaizen Foam!! How to customize it.
« Reply #13 on: October 25, 2019, 11:02 AM »
I don't know of many folks who do use those Surforms these days lol.

Offline jobsworth

  • Posts: 5895
  • Festool Baby.....
Re: Kaizen Foam!! How to customize it.
« Reply #14 on: October 25, 2019, 11:25 AM »
Looks like I’m gonna have to get another systainer and some kaizen foam to put all the kaizen foam tools in  [big grin]

Offline xedos

  • Posts: 117
Re: Kaizen Foam!! How to customize it.
« Reply #15 on: October 25, 2019, 04:35 PM »
Bodyshop guys round her still use a Surform.

Occasionally.

Offline presidentsdad

  • Posts: 43
Re: Kaizen Foam!! How to customize it.
« Reply #16 on: October 25, 2019, 08:12 PM »
I can smell it now!

A hot wire cutter works pretty well on polystyrene foam because the foam shrinks when it gets to it’s melting point. Polyethylene foam (Kaizen foam) shrinks less. It moves more from gravity than it shrinks.

Use a long thin knife with a fast reciprocating motion for polyethylene foam.
I suppose I could have used the hot knife for the whole thing, but it's pretty easy to use the regular xacto style knife and then use the hot knife to clean up the edges and bottom.  YMMV
PresidentsDad - TS75; FS1900; CT36; RO150

Offline presidentsdad

  • Posts: 43
Re: Kaizen Foam!! How to customize it.
« Reply #17 on: October 25, 2019, 08:13 PM »
P.S. Heating foam can release nasty fumes, so I recommend wearing a respirator mask with the right cartridges when doing that.

True, but if you are just smoothing the bottom of each cut out like I did, it's not really that bad.  I didn't use a mask [blink], smell was about like cutting some PVC pipe on your chop saw.
PresidentsDad - TS75; FS1900; CT36; RO150

Offline presidentsdad

  • Posts: 43
Re: Kaizen Foam!! How to customize it.
« Reply #18 on: October 25, 2019, 08:14 PM »
Is that hot knife blade replaceable?  If so it looks like it will take any type of "exacto" blade.
Seth

Yes they are.  If you check the first pic you can sorta see all of the tips that come with the kit.
PresidentsDad - TS75; FS1900; CT36; RO150

Offline presidentsdad

  • Posts: 43
Re: Kaizen Foam!! How to customize it.
« Reply #19 on: October 25, 2019, 08:16 PM »
FYI, I just got an email from FastCap about a new Kaizen Foam scraping tool.

https://www.fastcap.com/product/kaizen-scraper?utm_source=FastCap&utm_campaign=e5d10874a9-FC-kaizen-foam-scraper-20191024&utm_medium=email&utm_term=0_8c1f8244f9-e5d10874a9-412194413
I didn't see that before I did mine, that would work too!  Although it might not be as easy to get into the small pieces or tight corners!  8)
PresidentsDad - TS75; FS1900; CT36; RO150

Offline presidentsdad

  • Posts: 43
Re: Kaizen Foam!! How to customize it.
« Reply #20 on: October 25, 2019, 08:18 PM »
Looks like I’m gonna have to get another systainer and some kaizen foam to put all the kaizen foam tools in  [big grin]
After seeing how easy this was to do for this small project, I totally have about a dozen projects I need to do now.  [tongue]
PresidentsDad - TS75; FS1900; CT36; RO150

Offline jobsworth

  • Posts: 5895
  • Festool Baby.....
Re: Kaizen Foam!! How to customize it.
« Reply #21 on: October 26, 2019, 02:55 PM »
Looks like I’m gonna have to get another systainer and some kaizen foam to put all the kaizen foam tools in  [big grin]
After seeing how easy this was to do for this small project, I totally have about a dozen projects I need to do now.  [tongue]

I got a few I have to go back and clean up. That scraper will really tidy them up

Offline jimbo51

  • Posts: 465
Re: Kaizen Foam!! How to customize it.
« Reply #22 on: October 26, 2019, 07:06 PM »
When looking at the site, I saw that they now have Kaizen foam with a black surface layer and red or yellow interior layers. I will use black and yellow for DeWalt and black and red for Woodpecker.