rushfoam

It’s a Production Process

rushfoam — Tue, 24 Jan 2012 02:52:47 +0000

We have in our warehouse, at any given moment, at least 10 to 15 differents grades of foam. When foam arrives at our facility most buns (large blocks) measure 7 feet by 9 feet and are anywhere from 10″ to 45″ in height. We have huge bandsaws, one that cuts the buns vertically and one that makes horizontal cuts. One of our biggest challenges is cutting foam with the least amount of waste. Waste devours profits! When we’re cutting standard sizes we are able to make the best use of the buns with the least waste. However, cutting non-standard sizes can produce a huge amount of waste. It may have to be glued, it takes longer to produce and causes far more waste. Because of all these variables it also costs more.

This process requires planning but can prove quite challenging and fulfilling. It’s just one of the things we do everyday. It’s definitely not boring!

The economy is looking up! Really?

rushfoam — Tue, 17 Jan 2012 22:49:47 +0000

I don’t get it. The news, our government, business magazines & articles, all around we are being told the economy is looking up. Really? Well not in my neck of the woods! Maybe our government thinks if they say it we’ll believe it. Give me a break. Small business owners are not saying their economy is getting better. Companies are still downsizing, us included, and cutting costs where ever they can in an effort to make it through this “recession”. Sales are down in both the retail and wholesale industries. Large companies that have been around for years are filing bankruptcy. Many companies are reducing their inventories. Why even Wal-Mart has got more space between the aisles, which means they’ve got less inventory! Governments are failing. We need a new administration that supports small business. We need to quit sending our jobs overseas. Just don’t tell me things are getting better! I’m not dead or blind so I can see things are not getting better. But I do have hope that things will turn around because they always have. The ones that make it through will be stronger on the other side. I for one am looking forward to that.

Delivery Truck for Sale!

rushfoam — Sat, 07 Jan 2012 16:36:18 +0000

2007 Mitsubishi Fuso Truck. Excellent Condition, great for making city deliveries.

Happy New Year!

rushfoam — Sat, 31 Dec 2011 16:59:30 +0000

It’s hard to believe 2011 is past & 2012 is upon us already! I hope 2012 brings many blessings, opportunities & our efforts prove prosperous!

Merry Christmas!

rushfoam — Sat, 24 Dec 2011 16:21:29 +0000

Tis the season for Christians to celebrate the birth of our Lord and savior Jesus Christ. With that in mind, may your Christmas be merry and bright!

2011 Holiday Schedule

rushfoam — Wed, 21 Dec 2011 20:51:37 +0000

We will be closing Friday 12/23 @ noon. We will be closed from 12/24 through 1/1/2012. We’ll be back to work Monday 1/2/2012. Have a Merry Christmas & a Blessed New Year!

10 Steps to Making a DIY Upholstered Headboard.

rushfoam — Sat, 03 Dec 2011 14:28:00 +0000

Have you ever thought about making an upholstered headboard? It is not too difficult for an avid DIYer and you can design it exactly like you want. Every detail will fit into your tastes and decorating scheme. You decide on the height, the fabric, to tuft or not to tuft. You are in control! Here are 10 steps to making an upholstered headboard.

1. Decide on the size you want. The width should be a couple of inches wider than your bed. The width for a king about 80″, a queen 62″ and a full size about 56″. Your mattress might not be the standard size so be sure to measure. The height is totally up to you. Painter’s tape on the wall will help you visualize how it will look with pillows and comforter in place and in relation to your bedside tables and lamps. The following link gives several examples to help in making this decision. It also shows the various steps in the process.

Here is a link demonstrating the planning and execution involved http://blog.jenwoodhouse.com/home/2010/7/3/diy-upholstered-headboard.html.

2. Decide on the fabric. You’ll need enough to wrap around to the back allowing for the thickness of the plywood, 2″ foam, 3/4″ polyester batting, and turning the fabric edge under for a smooth, clean edge 3-4″ wide. Are you going for plain or tufted look? That decision may affect if you want solid fabric or a pattern.

3. Plain or tufted? If you decide on button tufting you’ll need to decide on the layout. Personally I think tufting looks best on solid color fabric adding the detail that makes it pop. Even though it doesn’t show up as well on busy fabrics it still serves a purpose, keeping everything taut and in it’s place.

4. Make a list and gather all the supplies you will need. Depending on your decisions you may need some or all of the following: plywood, foam, fabric, polyester batting, foam and fabric adhesive, tufting needle, button molds, button kit, button twine, staples, stapler, saw, drill, painters tape, and a metal or wooden cleat to hang the headboard on. The foam can be cut with a hack saw or the electric knife from your kitchen. You do not need a high density foam. A light weight, polyfoam works quite well in this application.

5. Cut the plywood to size (or have it cut). If you are tufting use painter’s tape to lay out your design plan on the plywood. Drill holes where the tape overlaps.

6. Adhere the foam to the plywood. Foam can be cut to the size of the headboard. If you decide to glue foam together to get the size needed be sure to follow the directions for a permanent bond. Both pieces of foam should be sprayed and then joined together.

7. Lay polyester batting on flat surface. Place foam/plywood face down on batting. Pull batting taut, begin stapling in center working your way out alternating sides as you go. Lay corners as flat as possible cutting out excess.

8. Press fabric and lay on flat surface. Place batting covered foam/plywood face down on fabric. Pull fabric taut and begin stapling.

9. Cover buttons and using a threaded tufting needle push the needle through the plywood, foam, fabric and button then push back through. You can pull taut and staple as demonstrated in the link or use a flat button slightly larger than the hole in the plywood to run the thread through (in & out) then pull taut and tie it off. Repeat until all buttons are installed.

10. Attach the cleat to the wall studs and the back of the headboard. Hang your headboard then stand back and admire your work!

Holiday Schedule

rushfoam — Fri, 02 Dec 2011 02:19:57 +0000

Our ofice will be closed from December 24th through January 1. We will return at 9:00 AM January 2. Merry Christmas & Happy New Year!