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I bought a used case on the cheap from a thrift store.
I cut out the lining and padding leaving the interior empty.
The lid of the case was filled with mattress foam cut to the exact shape
of the lid. As you can see I also cut out a spot for the laptop itself
to sit within when the lid is closed.
On the bottom half, the first layer of foam I used was soft foam. It was
not as soft as the mattress foam. More the consistency of 'floatation
foam'.
This was used for impact absorption.
On top of that layer I put a few inches of a harder foam. I found this
foam at Ace Hardware in the modeling dept. It is not a soft foam but rigid.
This was just to fill up some space. It just needs to be a rigid, yet
very light foam.
Then the top layer is also floatation foam (also called closed cell foam).
This foam is rigid yet slightly flexible. It is what many pool flotation
toys are made from.
This foam cuts very easily with an exacto knife and you can get very straight
lines.
Ones I got the foam in the shape of the case I measured all my gear and
drew it on the foam. Then I cut it out with an exacto blade.
I left spaces for all the cords and some room around all the vents.
I also cut through the previous layer of foam in the area that the laptop
would rest in. This was for all the cords. I left a lip that the laptop
would rest on and cut is so it would sit at an angle. I also lifted the
front end of the laptop, for a deeper angle with a square piece of foam.
The last
step was to paint it silver.
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