Posted by Steve Dedman on November 06, 2001 at 23:58:40:
A thought occurred to me on a way that might work to provide added protection for a horn in a flight case or a hard case. Just an idea at this point.
First, line the bell with as large of a trash can liner as possible, like those janitor-grade 55-gallon ones. Get it as deep into the bell as possible, and secure it somehow. Spray the inside of the liner with Pam or some kind of release agent. Now get 2 or 3 (or however many) cans of that expanding spray foam that is used for pipe insulation, and fill up the bag. It should conform to the contours of the bell, and provide a lightweight support to keep the bell section from self-crushing when the case is dropped. Let the foam cure for several hours, somehow mark the edge of the bell, then pull the liner out. The large end will have set unevenly, so you would need to take a hand saw and and cut it flush. Perhaps rig some kind of handle to facilitate removal. You could then cover the "plug" with whatever fabric you might find appropriate to keep it from marring the finish as you pull it in & out. The plug shouldn't add more than a couple of pounds to the weight.
Doesn't really help the valve section or the smaller branches, but it's better than nothing. Think it'll work?
SD