No foam Foamie experiment!
Posted: Fri Aug 12, 2011 2:37 pmMy Foamie is still on waiting on me to finish other projects before I can get started on it. So here is my 1st experiment. I started this right after 1st reading The original Foamie thread. Kind of a proof of concept based on someone else's experiment in that thread.
Anyway I have a sweet old grill I use for camping. It was bought many years ago used a few times and stored (forgotten) in the original box until recently when I pulled it down from the rafters and started using it again. The problem is carrying a dirty grill inside the truck. Trash bags not so good. I wanted light and strong and sorta weather resistant. Something that packed easy.
I took the original box and opened it up and taped the top flaps to extend the sides. Made a matching top. and covered it with TBII and an old bed sheet inside and out.
The materials.
The box partially covered.
I worked in stages covering 1 direction inside and out then letting it dry and coating the other direction In + out.
Glue coating for second ply.
The lid
Extra stiffener for bottom. Coated both sides.
Test fit.
After gluing I covered the whole thing with a coat of diluted glue. The process really saturated the cardboard so I left this thing out in the sun to cook in various positions off and on for a couple of weeks to really cure. Then I used some water based exterior paint I had in the cabinet and gave it 2 coats inside and out. I also cured this in the sun for a couple of weeks. Then I added an old boat cover strap as a lid hold down and handle.
It's now been on a couple of 4x4 camping trips and seems like it will hold up fine over the long haul. I can fit charcoal and started for a couple of days inside with the grill. It is really just a very strong weather resistant cardboard box. Very similar to a fiber drum case now. Only thing I bought was some TBII. Mission accomplished! Not too shabby for a 20+ year old beat up card board box. My wife figures she could stand on it no problem at all.
I intend to use the same process to make some other cases and also some lift out trays with dividers for my action packer style boxes that carry my kitchen stuff.
Anyway I have a sweet old grill I use for camping. It was bought many years ago used a few times and stored (forgotten) in the original box until recently when I pulled it down from the rafters and started using it again. The problem is carrying a dirty grill inside the truck. Trash bags not so good. I wanted light and strong and sorta weather resistant. Something that packed easy.
I took the original box and opened it up and taped the top flaps to extend the sides. Made a matching top. and covered it with TBII and an old bed sheet inside and out.
The materials.
The box partially covered.
I worked in stages covering 1 direction inside and out then letting it dry and coating the other direction In + out.
Glue coating for second ply.
The lid
Extra stiffener for bottom. Coated both sides.
Test fit.
After gluing I covered the whole thing with a coat of diluted glue. The process really saturated the cardboard so I left this thing out in the sun to cook in various positions off and on for a couple of weeks to really cure. Then I used some water based exterior paint I had in the cabinet and gave it 2 coats inside and out. I also cured this in the sun for a couple of weeks. Then I added an old boat cover strap as a lid hold down and handle.
It's now been on a couple of 4x4 camping trips and seems like it will hold up fine over the long haul. I can fit charcoal and started for a couple of days inside with the grill. It is really just a very strong weather resistant cardboard box. Very similar to a fiber drum case now. Only thing I bought was some TBII. Mission accomplished! Not too shabby for a 20+ year old beat up card board box. My wife figures she could stand on it no problem at all.
I intend to use the same process to make some other cases and also some lift out trays with dividers for my action packer style boxes that carry my kitchen stuff.
