Foam for toolbox shadowing

[BreeStephany]

I am hoping to start the somewhat daunting tax of shadowing my toolbox. I want to do a professional job, but hopefully without completely breaking the bank.

I have looked at a lot of foam options and am considering going with closed cell plank foam (Uline #S-20811). I estimate I would need 4 48x96" sheets, which would be $200.00.

I am going to try to find a brightly colored closed cell foam camping pad or something similar that is 1/4" ~ 3/8" thick as the base pad to go under the 1" planks.

Would this hold up well over time, or should I invest a bit more into something like Creative Safety's shadowing sheets?

 

[Tim37]

I got one of those mats they sell in the weight lifting section of sporting goods stored. I didn't shadow my Box but I did make some heavy duty drawer liners that dont wrinkle up or move around. That stuff should work for shadowing especially if you find a bright color to put under it

 

[WWheeler]

I've used the thin (3mm and 5mm) Yoga mats.

 

[BreeStephany]

I've used the thin (3mm and 5mm) Yoga mats.

I wasn't even thinking about yoga mats for the base layer, I definitely like that idea and can definitely find a good contrasting color with the wide variety of yoga mats available.

Thanks for the suggestion.

 

[T45]

If you can get to MEC (canada) they have well known 6mm EVA sleeping pads in bright colors. Yoga mats are believed (known?) to cause chemical/corrosive reactions to tools. This is according to one of the OEMs of toolbox liners, so maybe look into that before comitting to yoga mats.

 

[WWheeler]

If you can get to MEC (canada) they have well known 6mm EVA sleeping pads in bright colors. Yoga mats are believed (known?) to cause chemical/corrosive reactions to tools. This is according to one of the OEMs of toolbox liners, so maybe look into that before comitting to yoga mats.

I'm somewhat aware of the controversy surrounding long term health risks from direct skin contact with the PVCs in Yoga mats and most similar foam products (they do sell supposedly healthier Yoga mats to sweat and roll around on but all seem to be several times the cost), but corroding tools? That's a new one to me.

After several years of use I have yet to see any evidence of this. If it is true I'd like to see it, but Google fails me. Can anyone provide a link discussing / showing evidence of this?

I'd be surprised if most tool box liners aren't also made from PVC. If they are not I'll bet they cost a lot more than ones that are.

Edit:
Harbor freight: PVC
http://www.harborfreight.com/18-inch-x-72-inch-mesh-nonslip-drawer-liner-67055.html
http://www.harborfreight.com/16-inch-x-22-inch-nonslip-toolbox-liner-66948.html

Craftsman: PVC
https://www.amazon.com/dp/B01724LYVA/?tag=atomicindus08-20

Another brand: PVC
https://www.grainger.com/product/WESTWARD-Black-Tool-Drawer-Liner-Roll-22XP04

Looks to me that the most popular yoga mats are made of the same stuffs as some of the most popular tool box drawer liners. I've used the Craftsman and Harbor Freight tool drawer liners for a loooong time now and never seen any sign of corroding tools. Neither have I after several years now using yoga mats for shadowing. I don't suspect I ever will.

 

[Hagatronics]

Go to toolbed.com. they have a large database of tool shapes. You just type in the part# and place the shadow where you want it and it then arrives laser cut to perfection.

 

[WWheeler]

Go to toolbed.com. they have a large database of tool shapes. You just type in the part# and place the shadow where you want it and it then arrives laser cut to perfection.

I've seen some of the pics you have posted of your drawers and those custom foam boards are definitely a work of art.

[...]

Here are some photos and a short video of the drawer with the ratchets and extensions in it. I modified the drawer and built an insert for speeder bars as they take a lot of space.

<iframe width="480" height="360" src="http://s613.photobucket.com/user/hagatronics/embed/slideshow/Tools"></iframe>

Just curious. I've been to that site but really don't want to go through the whole process just to get an idea how much something like that costs. Besides, it says it only works with Internet Explorer and that's not likely to ever happen on any machine I own.

Soo, can you give us some idea of approximately how much those custom foam shadow inserts cost? I understand the cost probably varies a lot but a ballpark would be nice.

 

[Tim37]

Shadowing looks awesome it just takes up so much space.

 

[WWheeler]

I use the concrete floor joint strips sold at box stores.
They work fine and take spray glue well.
Cut easily with a soldering iron.

Trace with a pen, cut it out with a soldering iron.

I remember those drawer liners you're asking about as being so much a square inch that it came to 150 bucks a drawer.

I figured they're going to be pricey. Probably out of my budget and I suspect also for the OP who was looking for more affordable solutions than the $200 mentioned.

I used thin Yoga pad with a standard tool drawer liner under it so the colors contrast & I can easily see if something's missing. It looks really good to me. It's at work though or I'd post a pic.

Edit: I used thin 3mm (~1/8") & 5mm (~3/16") yoga mat because I only wanted just enough depth to hold tools in place opening & closing drawers in a stationary cabinet & I didn't want to waste the extra space necessary for finger holes to grab tools buried down inside the foam. It works really well for me.

Most other shadowed drawers I've seen seem to use a thicker foam more like a standard 1/4" thick yoga mat. That might work better if you need to be able to roll your box around or you tend to slam your drawers.

Aren't 'concrete floor joint strips' just a few inches wide. Are you shadowing a full drawer bottom with it?

 

[BreeStephany]

Shadowing looks awesome it just takes up so much space.

Yeah, shadowing does take up space, but at the same time makes tool inventory much easier and will likely be strongly encouraged, if not required by my job when I get to that point.

 

[T45]

I'm somewhat aware of the controversy surrounding long term health risks from direct skin contact with the PVCs in Yoga mats and most similar foam products (they do sell supposedly healthier Yoga mats to sweat and roll around on but all seem to be several times the cost), but corroding tools? That's a new one to me.

.......

Looks to me that the most popular yoga mats are made of the same stuffs as some of the most popular tool box drawer liners. I've used the Craftsman and Harbor Freight tool drawer liners for a loooong time now and never seen any sign of corroding tools. Neither have I after several years now using yoga mats for shadowing. I don't suspect I ever will.

The person making this point said it was as follows:

1) Yoga mats cause health issues to humans
2) Yoga mats are treated with chemicals to deal with #1
3) The chemicals in #2 are corrossive to tools.

This is consistent with what your research is showing you, BTW.

If you search in the "KRL liner replacements" thread I believe the discussion of yaga mats was in there.

Edit: found it

Thanks everyone for the feedback. Our Liners are actually the same ones Matco Tools uses in their boxes. I know they used to carry that light weight foam like Snap-On, but we sold that too and it was cheap and honestly not the best for a tool box that actually gets used.

Places like Harbor Freight mostly sells items made in China! And us being a US Manufacturer we really never know what's in the PVC.

We actually make yoga mats too and those do work great. However, some of the additives that make yoga mats non-toxic and skin safe are actually corrosive to tools. So although it works, if it isn't kept dry it may cause issues. That's why we don't recommend it when people ask about it.

I mean we sell our core stock at $.33/SQ Ft. The master rolls are made 72" wide, but for us to cut off 3 to 10 feet it is pretty easy. Our stock is about 1/8" thick and has moderate grip and decent cushion. But if you own a Matco Tool or Snap on tool box you would be used to it.

Although over the past year they have been going to China more.

 

[WWheeler]

The person making this point said it was as follows:

1) Yoga mats cause health issues to humans
2) Yoga mats are treated with chemicals to deal with #1
3) The chemicals in #2 are corrossive to tools.

This is consistent with what your research is showing you, BTW.

If you search in the "KRL liner replacements" thread I believe the discussion of yaga mats was in there.

Edit: found it

Interesting. So, if I'm reading that correctly, according to that the more expensive yoga mats that have been made to be free of the health concerns associated with PCVs are the ones that supposedly can be corrosive to tools? lol

I think I'll stick to my standard (& cheap) PVC tool drawer liners and Yoga mats for shadowing. I really don't care one iota about the PVC health issues as I'm not rolling around on them and people have been using PVC drawer liners for tools for just as long as there have been drawer liners for tools. As far as I'm concerned they have been tested tried and true.

I still wouldn't mind seeing actual evidence of exactly what type of foam or liner that was shown to have been corrosive to a tool. I tend to take someone trying to sell something's claims about such things with a grain of salt.

Edit:
One thing I forgot is when using the Yoga mat it wasn't as easy to cut with a new utility blade as I thought it would be, so I switched to using a #24 scalpel instead. I think I got a box of 10 or so on Amazon for ~$10. Cuts through the material like butter. Made it real easy to cut out the shapes perfectly.

 

[Hagatronics]

I've seen some of the pics you have posted of your drawers and those custom foam boards are definitely a work of art.

Just curious. I've been to that site but really don't want to go through the whole process just to get an idea how much something like that costs. Besides, it says it only works with Internet Explorer and that's not likely to ever happen on any machine I own.

Soo, can you give us some idea of approximately how much those custom foam shadow inserts cost? I understand the cost probably varies a lot but a ballpark would be nice.

The price varies on size and thickness (they have a single layer 18mm and a dual layer 31mm foam). Number of cutouts does not affect the price.

572x397 mm x 31mm was 59 Euros (about USD$63)
317x397 mm x 31mm was 35 Euros (about USD$37)

<a href="http://s613.photobucket.com/user/hagatronics/media/Tools/3O7A0941_zpsxjinaxax.jpg.html" target="_blank"><img src="http://i613.photobucket.com/albums/tt218/hagatronics/Tools/3O7A0941_zpsxjinaxax.jpg" border="0" alt=" photo 3O7A0941_zpsxjinaxax.jpg"/></a>
<a href="http://s613.photobucket.com/user/hagatronics/media/Tools/3O7A0940_zps53cwqwbv.jpg.html" target="_blank"><img src="http://i613.photobucket.com/albums/tt218/hagatronics/Tools/3O7A0940_zps53cwqwbv.jpg" border="0" alt=" photo 3O7A0940_zps53cwqwbv.jpg"/></a>
<a href="http://s613.photobucket.com/user/hagatronics/media/Tools/3O7A0927_zpskurjczi0.jpg.html" target="_blank"><img src="http://i613.photobucket.com/albums/tt218/hagatronics/Tools/3O7A0927_zpskurjczi0.jpg" border="0" alt=" photo 3O7A0927_zpskurjczi0.jpg"/></a>

 

[T45]

Interesting. So, if I'm reading that correctly

I honestly think you're reading it in a way that favors your own preconceived outcome, not really the way it was written.

The source quote is pretty specific--the guy writing manufactures yoga mats. If you do use yoga mats (and I have used them as well, they work well), do not put your tools away with any moisture present.

Specificaly in this case, there is another factor at play. When you shadow a box (the subject of this thread) you are not just using a yoga mat as a box-liner. You are using the mad as the base for a shadow-foam panel.

The cutouts in the panel (say 1/2 inch thick black EVA) is then assembled to a thin backin sheet in a contrasting colour (say, 1/4 inch yellow EVA). The issue with this is that using a yoga mat for the part that isn't cut out means any moisture trapped in those cutouts is less likely to dissipate than with usage like a normal box liner where the tools just sort of sit on the liner.

In a shadowing application, the tool sits in a hole and can be pretty well sealed in there, which means a drop or two of moisture is more problematice if its setting off chemical reactions.

Anyway, I scrapped yoga mats after peeling a wrench off one and it has some minor rust starting (dry box, indoors, only subject to humidity fluctuations as best I know). It was very minor rusting spots but EVA foam is no more expensive that yoga mats (I just had the latter lying around).

The harder issue with camping mats is they are typically 3/8 or 1/2 inch or thicker and you really need a specialist retailer to get you the thinner ones. Besides MEC, the specialty outdoor/retail stores tend to be more upscale with higher boutiquey type prices.

One think I'm experimenting with now is actually tyvek (bright white), and this may be useful for a backing liner. or even a chemistry barrier on top of a yoga mat. The tyvek (ie, housewrap) is semi-permiable so won't trap moisture on the surface the same way. It's also thin so it doesn't add height. Its not padded or grippy by itself, but in the context of shadwoing the tools would be secured by ther main foam cutouts in any event.

 

[stuk4x4]

Just a question, does your new employer have a specific list of tools that you are required? Many Aviation companies require certain box set-ups. It’s worth checking into before you spend your time doing it, some companies will pay you to silhouette your toolbox (my buddy was given the last 30 mins every day for 2 weeks to get his box squared away on the clock). Also I have used Snap-on foam with great results over the years, and it has been very durable. This is not an area that you want to skimp and redo later on.
Just my 2cents.
Good luck
Walt

 

[Brian80]

I used the perforated black drawer liner that you can get at any box retail store, then used the blue foam mats from Walmart. My drawers look just as professional as the guys who used Snap On Foam. I'll see if the wife can send some pics and I will post them later for you.

 

[Cypherian]

OP ,

This subject has been kicked around many times.
http://www.garagejournal.com/forum/showthread.php?t=309448
http://www.garagejournal.com/forum/showthread.php?p=5249522#post5249522

I posted this in the first thread : The snap on foam is very expensive check around. This is what we used when I was the CTK NCIOC in the Air Force. The numbers may have changed but call MSC they can tell you what they are now. These were 4'x8' sheets. You may also wish to create an inventory sheet or TIL as It is or was referred to. I do not know civilian non military air craft mechanics rules but some of our contractors were required to do both foam and provide a TIL. If you notice the blue foam has a pressure sensitive backing so once it is trimmed cut out you stick it to the yellow and you get a high contrast back for speed in inventory.

Using other types of foam / less expensive can also work but it can also bite you in the ****. We found after some experimentation that some foams broke down due to the chemicals / petro chemicals the tools might have on them in them or on the gloves of the mechanic getting the tool out. We also found some of the heavier tools structural repair has ie bucking bars and rivet guns would crush the less expensive foams down permanently . It was not a big issue but it would cause separation between the foam layers and allow other tools in the drawer to slide under and between the foam sheets. Food for thought from a veteran of foaming more tool boxes / Vidmar cabinets then I care to think about. We did the layouts on butcher paper cut to drawer size with consideration on weight of tools and most used . Then transferred it to heavy cardboard and finally to .025 stainless sheets so when new foam was needed for a drawer we had the layouts and it was quick and painless .. mostly lol. You can cut the foam with razor knives have a lot of blades handy , dremel with an upcut spiral flute bit ( keep the tool moving heat is your enemy ) and several other ways that get more expensive as you go or smell up the place lol. YMMV

Blue Foam w/PSA 4 Sheets 04675666 MSC
Yellow Foam 4 Sheets 84538388 MSC

CYpher

 

[donpauli2]

I am hoping to start the somewhat daunting tax of shadowing my toolbox. I want to do a professional job, but hopefully without completely breaking the bank.



I have looked at a lot of foam options and am considering going with closed cell plank foam (Uline #S-20811). I estimate I would need 4 48x96" sheets, which would be $200.00.



I am going to try to find a brightly colored closed cell foam camping pad or something similar that is 1/4" ~ 3/8" thick as the base pad to go under the 1" planks.



Would this hold up well over time, or should I invest a bit more into something like Creative Safety's shadowing sheets?

A " professional" job wouldn't usually be in a " professionals" box but it is cool as heck. Once I retired I too am working on this. Snap-On does sell drawer liner already made for this and laminated together I chose the yellow bottom layer for my Royal Blue boxes


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[BreeStephany]

I just discovered Kaizen foam and almost immediately became sold on it as the solution to shadowing my box. Its super cheap, less than $150 to shadow my entire box, so I definitely think I'm going that route.

 

[greasyfingers01]

Check out the foamfactory.com I've bought quite a bit from them for various projects. Their prices are decent and free shipping over $75

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[Wyoming09]

Here is another option I happen to come across and remembered this thread:

http://foamfittools.com/detailsB1B.php