Back in the 90’s there was a brief mention of a Taunton toolbox competition finalist who built his winning piece out of a guitar case. The guitar case was lined with foam in which the cabinetmaker had recessed perfectly shaped spots for his hand tools. He did not cut the recesses, but instead formed them around the tools while the foam was undried and the tools were in place. Does anyone have any experience doing this? Or might anyone guess how it would be done?
He fit multiple planes, chisels, mallets, drawknives, etc.
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There are various expanding foams, usually polyurethane, that are used for this sort of thing. However, I think it would be tricky to mold the foam directly to the tools. Even with a release agent, you'd risk the foam enveloping the tool so thoroughly that you couldn't remove it.
In any case, it's a fairly standard industrial process, but I'm not aware of any kind of do-it-yourself products, except for the foams that are used for insulation and air sealing in home construction (see http://www.tigerfoam.com/, for example). Those foams are probably too stiff for this application.
-Steve
You wrap the tool in saran wrap or equivalent before bedding it in the foam, or you can do it upside-down. Place the tools in a form the shape of your box in the position you want them in, and wrap velvet or whatever (good side down) around the tools and up the sides. Fill with foam, screet off the excess, wait tiil hard.
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