Foam for toolbox

[upper_tanker]

Hello all. I just pulled the trigger on a 56" U.S. General from HF. I would like to get some 2-layer cut-out foam for 5-6 of the drawers, plus maybe some drawers in my other 2 boxes. I was wondering if there was any cheaper stuff than the $35-$55 per-sheet stuff on Amazon. It doesn't have to be super rigid and tough, as I'm just an occasional dabbler. I'd like to reorganize my other 2 boxes that I have now and make it easier for me to find the smaller tools by minimizing the need to go digging.

I feel like this subject has been beat to death numerous times, but I can't seem to find anything with the search. I guess I just didn't want to spend $200-$300 on foam if I could get it for $100 or so.

Also, I realize that going this route takes up more space than other ways. I plan on only using this for smaller tools (screwdrivers/files/punches/extensions).

If $35-$55/sheet is the norm, then I guess I'll slowly buy them in increments, but figured I'd ask here in case there were cheaper options.

 

[TuxThePenguin]

another option is https://www.thefoamfactory.com/closedcellfoam/closedcellfoam.html

layer 2+ layers yourself and cut one or more of the layers

you can use most of those closed cell materials.. neoprene, gym rubber, EVA, just about anything there.

I'm not sure if this is the BEST option, but it's one option.

 

[upper_tanker]

another option is https://www.thefoamfactory.com/closedcellfoam/closedcellfoam.html

layer 2+ layers yourself and cut one or more of the layers

you can use most of those closed cell materials.. neoprene, gym rubber, EVA, just about anything there.

I'm not sure if this is the BEST option, but it's one option.

Thanks for that advice. I didn't even think about that! Any idea on what adhesive I'd want to use? Would the 3M stuff that I use for headliners and fabric work, you think?

 

[TuxThePenguin]

probably something rated to work with vinyl. I don't think I've used the adhesive you asked about, so I'm not sure.

I'd personally probably use 3m 80 spray (not super 77, but rather the one for vinyl), but I'm not saying you have to buy that stuff, that's just what I happen to be familiar with.

 

[seber]

I would use polypropylene, as it is impervious to pretty much anything other than certain solvents. However, it is also impervious to adhesives.

 

[FuzzyTiger]

Kaizen foam is an option: https://www.fastcap.com/product/kaizen-foam

Another decent option:
https://www.foamfittools.com/

For the total diy approach I would recommend Eva foam. It's used for gym mats and things like that. Easily available in decent sizes. It'll resist oil and other things and cleans up well and is also quite durable. You'll have to cut it yourself of course. I believe this is the same material used for most nicer foam inserts you'll receive with tools.

 

[r.phil]

I've bought tool foam inserts from Shadow Foam, for as less as £15 for three foams in different sizes. And they were really good and durable. I bought them last year and still have them in my toolbox. I believe they provide shipping to the US as well. These foams are made of polyethylene so it wont damage or react with any of the items that you store.