DIY Foam Insert Toolbox

So I’ve always been a fan of a well-organized toolbox to take with me to bike races and weekend bike trips. Abbey Tools a few months ago released a Team Issue Toolbox (www.abbeybiketools.com/produc...) with a well-organized foam inserts arranging many tools. After seeing this tool box it inspired me to build my own foam insert tool box. With some additional ideas found on Tool Box Wars Instagram ( toolboxwars...) I started my own Tool Box Project. For those that are interested in building their own foam insert tool box for themselves you are welcome to watch my video to learn how I did it and what I learned for next time.
Blog Post: mattcassell.ca/diy-foam-inser...
I have no association with the website links listed below.
_______
Materials:
Water Proof Case (eg. Pelican Case) - www.canadiantire.ca/en/pdp/ma...
Kaizen Foam Sheets - kaizencasesandinserts.com/col...
Polypropylene Webbing - www.amazon.ca/gp/product/B01K...
Acrylic Sheet - www.amazon.ca/gp/product/B01D...
_______
Tools Used to Make The Box:
- Utility Knife
- Carpenter’s Square
- Permanent Marker
- Need & Thread
- Hot Glue (Bad Idea!!!)
_______
Tools in the Tool Box:
Lid:
- Mastercraft Side Cutters
- Mastercraft Needle Nose Pliers
- Park Tool VC-1 Valve Core Tool
- Park Tool VP-1 Vulcanizing Patch Kit
- Cassette Tool
- Park Tool SD-Set Shop Screwdriver Set
- Accu-Gage 0-30 psi
- Park Tool SW-0 Spoke Wrench
- Scissors
1st Middle Layer:
- Park Tool SR-1 Sprocket Remover/Chain Whip
- Open Ended Wrench 1”
- Tire Levers
- Fox Shock Pump
- Park Tool TWS-1 Torx Wrench Set
- Maximum Metric Hex Key Set
- Bicycle Shaped Bottle Opener
- Mini Maglite (Cub Scouts Canada Edition)
2nd Middle Layer:
- Unior 1666/2DP Rotor Truing Fork
- Unior 1720/2DP Master Link Pliers
- Pro Chain Tool
- Park Tool CC-3.2 Chain Checker
- Axiom Chain Ring Bolt Wrench
- Bike Cable Cutters
- Mastercraft Pliers
- Park Tool BBT-22 Bottom Bracket Tool
- Mastercraft Utility Knife
Bottom Layer:
- Small Parts Container 1 (Grease, Chain Lube, Carbon Paste, Shimano Bleed Kit)
- Small Part Container 2 (Miscellaneous Parts, cable crimps, cable ferrules etc.)
- Open Ended Wrench 7mm/8mm
- Nalgene with Shimano Brake Fluid
- Spray Bottle with Isopropyl Alcohol
- Park Tool PP-1.2 Hydraulic Brake Piston Press
#diy #toolbox #bike

[@marcod.9629]

Amazing toolbox

[@mcassellmtb]

Thanks!

[@MrCoscarelli]

Great video! Thank you

[@mcassellmtb]

Thanks!

[@DonnySimpanero]

I love to see peoples custom toolboxes with the foam. I have an Armstrong USMC GMTK tool kit and it’s a heavy sucker. 106 pounds lol.

[@mcassellmtb]

Nice! This one only weighed about 30 pounds or so if I recall.

[@BenDunlop]

Thanks for this detailed vid, very helpful. I'll be doing the same

[@mcassellmtb]

Thanks!

[@davidcurtis6347]

Noice job bro.

[@mcassellmtb]

Thanks!

[@comcodyrocks]

An alternative to the hot glue would be contact cement. I don't know what brand you have in Canada but in the states the good stuff if Barge Cement. It's used to glue soles to shoes and is incredibly strong if applied correctly. The trick is to apply to both surfaces, let it dry until it's tacky, then (carefully) sick them together. You would need to rough up that acrylic with sandpaper first though. Another alternative is spray adhesive like Super 77 (I think that's what it's called) but I've never used that stuff so I don't know how strong it is, I just know it's kinda messy.

[@mcassellmtb]

Thanks. I've been meaning to try a test with regular white craft glue. I bought some for another project. Contact cement is agreed another option. Have you used it on this type of foam before? I've used spray adhesives before and was my first thought when the hot glue didn't work.

[@garrettswoodworx1873]

@@mcassellmtb Ironically, hot glue would probably work perfectly for the handles.

[@butchgreene]

3M makes a spray foam glue for this exact application. #74 I believe. If you need it just sheet to sheet, #77 is in stock in home improvement stores.

[@jimhansen5395]

Good video - working on a similar project - I wonder if double sided velcro would work for the handles?

[@mcassellmtb]

I don't see why not. Would be quicker to install the handles for sure. Might collector dirt faster depending on where you are using the tool box.

[@mtbkc8975]

Great vid. Never done this but wonder if a Dremel tool would be useful for clean cutouts for the tools?

[@mcassellmtb]

I've never tried using the Dremel. I'd be concerned it would snag and tear. I do have some scraps left. Maybe I'll try it one day.

[@janeblogs324]

Way too much mess. Carbide bits will clean cut

[@WillisZzz]

I have one, love it! Much cheaper than the pelican brand. Have you ever tried removing the lid? I need to remove the lid to perform some mods but I don't want to ruin it...

[@mcassellmtb]

So much cheaper! And they regularly go on sale at Canadian Tire! And I've never taken the lid off.

[@LucaDelRe]

Hi where is possible to find a foam?

[@mcassellmtb]

Here is where I got the foam from kaizencasesandinserts.com/?gclid=CjwKCAiAhKycBhAQEiwAgf19eomk-LyITfhdVXyK5Z3tlMY3eyJz7ptyIrlrLp6fsykijIGKQIZicBoCnMQQAvD_BwE

[@techdavis]

Not sure why you didn’t slot the polypropylene for the handles. That way there would be more support for the layer, and the glue issues would be nonexistent

[@mcassellmtb]

Yeah. There were probably a number of ways that I could of done this. But this what I came up with at the moment.

[@Volcker1929]

3M Super 77 or Super 90 is best for foam.

[@mcassellmtb]

Awesome! Thanks! Will look it up.

[@garrettswoodworx1873]

LOL! You beat me to it! I've used Super 77 and it works great. Was going to suggest the same.

[@RoadkingNZ1]

I would have used a spray adhesive

[@mcassellmtb]

Considered it. Past projects, spray adhesive hasn't held up well longer term. But the materials being glued were different.

[@sv2697]

I find that it's cheaper to buy a case with foam then buying foam for some random case u have.

[@mcassellmtb]

Fair enough.