Well,
Having shadowed several thousand tools I can speak to this fairly easy some has been covered:
PBCampbell "People who do aircraft maintenance are required to "shadow" their toolboxes to aid in accounting for all tools. It's a space eater though so outside of aviation you seldom see it. "
This is very true Space Eater and a Half, though it is done in other fields where accountability for tools and equipment is required for the safety and operation of other equipment.
AdamC.'s Thread : Very good primer on doing your box and some really good suggestions on not doing the whole drawer, finger cut outs, ways to store wrenches to take less space etc.
You have to be careful of depth of cut for smallish items and sharp pointing things like ohhh scribes :}
osaapamerica: Good idea though I would venture it is costly for an individual to do for his own tools.
We had the laser system toward the end of my tenure once everything is scanned in and dimensioned yes it is very fast and very clean but costly for a one off setup.
Now my own observations:
Warnings:
Pick the correct foam type and foam density for your tools some foam does not do well with petroleum distillates and will melt other foam is to soft and the weight of the tool will deform it permanently and allow it to move around causing you to have to redo it.
Foam and sealants or adhesives do not play well if the tool is not really cleaned it will glue itself to the foam.
Foam and metal shavings / dust do not go well together it gets imbedded and you can not get it out though it does depend on the foam you choose some is less susceptible to this.
Do your lay out on paper first set it in the drawer and set the tools on it add a sheet of material that is the same thickness as your bottom foam. To get an idea of what tools might be able to live in what drawers.
Do your cut out with xacto or dremel unless you are going to spring for someone to scan and laser cut your foam.
Cut out your top sheet then adhere the bottom sheet to it do not stick them together then try to cut and peel they make specific foam for this but it is way to expensive and to be honest the adhesive left after you cut the top sheet collects stuff.
PM me if you have more questions. I can dig up the part numbers for the AF blue and yellow foam if you like lol it is half inch thick.
Cypher
