HOWTO: Make Drop Box Covers

[TrooperTim]

Supplies:

• Flat sheet of plastic or any material you prefer to use for the drop box covers
• Foam
• Sew on Velcro
• Sticky Velcro
• Glue (any brand CA glue works well)
• Rotary Tool (Dremel), Scissors, or Box Cutter
• Pencil
• Needle and Thread (optional)

 

 

You can use a variety of materials for the covers. I used a spare sheet of ABS plastic provided from my armor kit.

 

(1) Measure the length and width of the drop box.

 

(2) Draw two rectangles on your drop box cover material from the measurements.

 

(3) Cut out the covers.

 

(4) Cut out 2 rectangles from 1/2 inch foam using the measurements. I used 1 inch thick foam and cut one rectangle then VERY CAREFULLY cut that vertically in half to make two 1/2 inch thick rectangles.

 

(5) Loosely sew a piece of Velcro to the foam. If you sew too strong the foam will compress. You can glue the Velcro to the foam if you prefer.

 

(6) Glue the foam to the covers.

 

(7) Apply sticky Velcro to the inside of the drop boxes.

 

(8) Place the covers in the boxes.

 

Done!

[ZeroRoom[TK]]

Great tutorial Tim! I was just mulling over this one myself - I like your technique. What made you decide to make them removable with Velcro? (as opposed to just permanent with glue)

[bobojuice]

Not a bad idea. I may be doing this myself with my next two builds. I'll probably do it permanently though.

[TrooperTim]

On 10/14/2011 at 3:54 PM, ZeroRoom said:

What made you decide to make them removable with Velcro? (as opposed to just permanent with glue)

 

My helmet camera remote fits perfectly in the drop box. When I'm not recording, I can put the drop box cover back on.

 

 

[ZeroRoom[TK]]

Brilliant! I do love your helmet cam vids

[Daetrin[Admin]]

+1 Pretty neat idea