DON'T DO What We DID! How To Cut Foam Inlays for Power Tools and More.

We were looking for perfection in creating these foam inlays for our tools, but it's not exactly cheap. We used our XTool D1 Pro 20W Laser to cut the Milwaukee Foam for our PACKOUT box. The lines are near perfect for each of the tools and no manual tracing is necessary.
Milwaukee Foam Trays: homedepot.sjv....
XTool D1 Pro 20W Laser: amzn.to/3WPvQAR
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[@RayW808]

Manufacturers should offer free pdf/cad images for free.

[@darrenbrumfield7717]

Imagine if they offered free pdf/cad files for $4.99

[@jcoats5529]

Or just sell the cut outs for all their tools and you'd just arrange them and only have trim the outside to fit inside the took box as desired

[@pedrosmits]

The perfect cut-out would be with an copy jig. Perfectly making the contour of the stuff you like to put in.

[@bigd835]

why not just put the template on the box the tool comes in ? your idea is a good one.

[@geekazoid]

its very easy to do this yourself by tracing the item and scanning it with a scale mark, then import the scan into CAD and scale it

[@jamespetty9545]

When I worked at Pratt & Whitney over in Columbus Georgia. They had an cnc machine and the technician would lay our tools out in the drawers. The way we wanted them and they would cut them out. They had a yellow backing so when you pull the tool out the yellow would show and you knew that there was a tool not in that box

[@CheapCheerful]

How to cut foam - just use a laser cutter. Oh, I'll get just it out of my toolbox!

[@Dragonited]

He litterally say that you can use the same pred techniques to print out on paper and attach to some cardboard that you can use to cut it with.

[@Mett-wt3xj]

Thank you for wasting our time. Everyone knows you can cut it with a laser. Very misleading title.

[@kitchtangov]

What do you mean? Everyone on KZbin has a laser cutter

[@p-force7732]

Great Idea! Thanks for the share. I am just about to the foam stage on my tough system build. I did one tray the hard way but didn’t live the results. I have a friend with a laser cutter. I’ll have to trade favors for some custom foam work.

[@lannybrasher2452]

Cut the foam in half horizontally first, then let the Lazer cut the design completely through the top half, then glue the two half's together. Smooth, and no digging out.

[@demjay]

I totally thinking the same thing 😁👍

[@seanm4075]

I have an easy solution for less than a dollar... Buy a box of tooth picks & place them around your items, specifically at corners & anywhere the item juts out or in... no offsets & you can reuse them for each item...

[@NJTreeSharks]

Every tool Milwaukee sells that can fit in a PACKOUT should have a perforated cutout of the tool on every box the tool comes in for the PACKOUT. Example When you buy a subwoofer there is a perforated circle you can cut out and apply to your subwoofer box to trace it out so your sun fits perfectly. It would cost Milwaukee nothing to add a perforated outline of the tool on the box that it comes with.so you can trace to packout foam or a regular toolbox foam.

[@shaunsims-p2z]

Should but they want you to spend a fortune buying all the extras.

[@shaunsims-p2z]

They think every tradesman is loaded. It's exactly the same thing as why vans cost more than a nice car and the things are rust buckets

[@8chuck21]

Yea because these pack outs are to expensive tbh

[@blakekelley899]

@@shaunsims-p2zconversation vans or work vans do not cost more then even a decent new car🤣

[@daifeichu]

I haven't cut a lot of Kaizen foam but a scalpel was very easy to use. Even tools with dipped/rubber handles won't be a problem. When cutting you keep the blade almost buried so you don't cut into the handles. So far I've done a couple screwdrivers and the Milwaukee install driver and it's four attachments. It was fast and accurate. Turned out really nice.

[@delanezdelanez5253]

I always just made a shape exactly the length and width I needed then manipulated the background image to match, just a thought. Also if you have a scanner on a cheap or expensive multi function printer that will get you a perfect objective.

[@nathanwolf5547]

Use thinner layers of foam. New lasers are now enclosed so the smoke isn’t a problem.

[@ronaldraymond7037]

How would two contour gauges work to trace out a tool??

[@robertmunafo5039]

Great vid. I'd use 3 layers however; bottom thinner dense layer uncut, second layer for only deep cuts, top layer for the cuts you see. Just label each cut a different color in Lightburn and turn on one at a time as you swap out the foam. Put a non-cut layer in Lightburn to draw a box the exact size of the foam and position everything the way you want it within that box, position laser at the bottom corner and select "start cut at present location" This helps you align the two foam pads as you swap them out before cutting. Laser cut through each layer one at a time and mid layer cut is kept in perfect position in relation to the top layer. glue together.

[@kylehughes1619]

Hey brother nicely done. That was actually pretty ingenious. And I like that you showed us the cheap way first instead of making us wait till the end.

[@andrewbrown8148]

Great info~! That's a cool way for getting the tool outlines. Using a laser to cut out the recesses isn't crazy at all. What IS crazy is that I'm going to try/use this method for obtaining tool templates to use with my Shaper Origin~! Once I have a good outline, then I can use Shaper Trace for importing it into the workspace to make a .SVG file. Always another way to skin the cat, eh? Thanks for this video~!

[@psfanboy79]

It looks amazing, so pleasing. Such a great idea of finding picture and using thar

[@alandohse1977]

Very helpful! Just purchased a D1 Pro, but haven't used it yet. Thanks for the vid! Al

[@ronaldraymond7037]

I used an iPhone 15 pro max when you take a good picture you can long-press and swipe a bit and you’ll see a white shape encircling just the tool. Now save it and take that into photoshop for sizing. Very quick way to get a good template. As long as you can fit it on a 8.5” x 11” print out. A 13x19 printer would be needed for the bigger tools. I put the 5 tool M12 and a m18 hammer on one of those.

[@tripstomexico9770]

I just had a shop light bar about 4 feet on top of the foam and used the shadow outline of the actual tool to trace it with a silver marker🤷🏻‍♂️

[@tomwill_or]

On your phone, turn on the level crosshairs and set zoom to 1. Then take a centered photo as well as a couple others. Pretty quick and easy to overlay them and now you have a custom layout, instead of having to hope the online flat images are correct.

[@karenblanck7726]

Why not get the picture from manufacturer site?

[@phillamoore157]

A $1K laser, guided by a $2500 Mac book, to cut $25 dollar foam....THAT's your suggestion????

[@buddyolpal9615]

Felt like I was the only one

[@kitchtangov]

😂😂

[@digitalcowboy]

😂😂😂

[@Slowhand871]

These videos are for weekend warriors. Contractors are happy if we actually get our tools back in the van or truck.

[@phillamoore157]

@@Slowhand871 100% correct on both points. But, my original point (although made in jest) still applies. As a weekend warrior myself, I’m not about to drop $3K-$4K into tools, laser, computers so I can precisely cut my $15 slats of foam. I’d rather spend it on killer tools (although, obviously that wasn’t this guys message to us). I dig what his channel is doing, and the video was interesting from a technical standpoint….I just couldn’t help but notice the irony to it.👍

[@MarkThomasBuilder]

Hey Tim, just noticed you're over 100K subs. Congrats, man!🙌

[@Shoptoolreviews]

Thanks Mark. Appreciate it brother. It feels like it took forever.

[@marknelson7451]

Good Video. One suggestion is to photograph the tools with backlighting so they appear as a dark shadow. the longer the lens (mm) you use, the more accurate the outline. You can also include a ruler for easy adjustment in computer software. Do you know if this type of foam is safe to use with a laser? I couldn't see what the actual foam is. Some foams give off toxic fumes that will damage laser and damage the operator. Thanks! PS: I have that laser.

[@chrisludwig5101]

Anyone try to use a router with a 1/8 or 1/4 inch bit ? Freehand the outline, with a vacuum attachment (could be messy) would give you nice flat bottom.

[@markk3948]

That laser cut really fast and deep wow I thought you had it on high speed at the start lol. People can also use inkscape that has a trace bitmap option then you can save it as a svg file. Another awesome video thanks :)

[@jasonbabila6006]

I always cut 1/8” inside of the lines for a tight fit but keep the blade of what ever you are using to cut out the hole straight, over time the foam will loosen and create a memory.

[@therealJohnAcree]

Great video. Has anyone tried this with GIMP? I'm trying to make this work for the installation driver.

[@JadedMax]

Holy shit, thanks man! This worked beautifully

[@psfanboy79]

What about a router? Would that work? Instead of having to dig with your fingers?

[@TheCharleseye]

Or throw them all in a bag, since wasting space with boxes that have lots of dead space around the tools, is exactly what we were trying to avoid when we all threw away the molded cases that came with our old tools.

[@Goose-Grip]

Tim thanks for pitching my work light. I am going to make the Goose-Grip work light be able to support multiple battery platforms. So that said, can anyone reading this or Tim, if you know...what is the order of popularity of electric tool brands. Milwaukee then Dewalt, then ? and then ? and where do you think Snapon falls?

[@Myrddraalfade]

I get my flat outline by putting the tools on the scanner bed of my workshop printer, a Canon PIXMA All-In-One (£36 from Amazon AtM). No manipulation required, just a 1-to-1 photocopy.

[@christrighteousnessalone7512]

Great cut ....shame you butcher taking out the centre bit ...you should have routered out the inner bit to get a neat removal and finish!

[@thereloadingcraft]

Super cool way to do it! Thanks for sharing with us!

[@RahulKumar-vh4xr]

This is awesome, and the diode laser can do work on foam. The only suggestion I have is that unless you know for a fact that the foam is laser safe EVA - I’d get a vented enclosure.

[@SymonSaysTV]

Working so hard for the perfect outline cut and doing such a poor job for the bottom makes it all worthless.

[@mostlikelywedoitservices6926]

Make a rectangle box the length you want. That will be your reference instead of constantly dragging out the tape measure.

[@dustinedwards7995]

use two pieces of foam and glue together

[@russthompson7994]

I think a CNC would make a perfect cut and you won't have to dig out the foam. Prove me wrong! 🤣

[@jasonstaudt5290]

That was 20 minutes I will never get back. First 3:25 was a waste of anyone's time. Should have been called "Hardest way to make a cardboard template"

[@davidmarks4198]

2:25 starts explaining how ….

[@andyespenan5919]

If cutting thru an entire layer, I use an electric fish filet knife.

[@ghorbanalirazmjou8591]

Thanks 😊

[@jls1znv9999]

Congrats to Texas winner.

[@jf18jony]

CNC? 🤔

[@thomast7748]

I have a much better solution: 3d scan it, make a boolean in your CAD software, and 3D print it in 24K gold.

[@conanamaddog]

Could you share the file?

[@timlist4173]

Like everyone has a laser cutter.

[@2point..0]

cONGRADS ON THE 100k SUBS~~~

[@franciscosalazar7439]

I watched 5 mins in until you got to laser 😂

[@bitsmart...]

shop tool reviews! is your head okay!? to cut few pcs of foam you suggest to buy laser cutter for 569 USD!? ha! ha!

[@EyanSchreibman]

Is there anyway to get the file, I follow your steps but the layout comes out to big or to small.

[@CorvetteTrev]

This is killing me, I have a big thick one, and I just want to cut ✂️ in HALF , so I can use two to go in two separate trays

[@CraigFairbanks-n4i]

Engineer?

[@th3m1ke]

Great job though Id be careful cutting the foam without a fume extractor, burning that material is pretty nasty.

[@yuriyakpp]

вот у меня в хозяйстве еще лазера не было)))

[@underdog2400]

I just use a projector. So much easier than wasting trees

[@FirstLastOne]

This was painful to watch because everyone around was yelling at the screen, "JUST DO IT ALREADY"!!!

[@NeerajLalu]

will most likly end up costing more than the tools

[@ImionsaeXwb77]

Yeah i just got all them equipment laying around to do this... For real? who you fooling with on how to cut inlays, sure ain't the average joe's

[@michaelwilliamson6869]

$9 foam cutter wi do the same thing......😅😅😅😅😅

[@kr4t0sg.28]

That's cool but i personally don't own a computer much less fancy gadgets.

[@keithklickstein7102]

just use a scanner, most people own a scanner/printer... easy to do

[@capone_rd_809]

The first thing is, is to not use cheap foam

[@GunzCoty]

Or just place the tool down and outline it with tooth picks.

[@TimAlfrey-kw1md]

Awful lot of trouble to have a place for your stubby tool!

[@Mihalyofficial]

What an incredibly complicated way to solve an issue...and who has a 10 000 dollar laser cutting machine anyways? come on

[@kauaichefservice995]

I guess everybody has a $10,000 laser cutter and is a photoshop expert nowadays….back to the Matt knife for me…

[@skiphorni]

Stop yelling. You're much easier to listen to when you just talk.

[@Shoptoolreviews]

That's not near as fun. lol. Sorry for the yelling. Thanks for watching.

[@luc.s08]

🔝🔝

[@thev8744]

Y’all spend to much time with tools and no women

[@molson62]

TOO MUCH WORK!!!

[@Notmy00000]

🙏🙏🙏🙏🙏👍👍👍👍👍👍

[@markm0000]

Why does this guy always scream on video.

[@KosmicHRTRacingTeam]

Nope. Done it both ways. First of all, the harbor freight sheets are 4 for $9 (not $15) and yea, you do 2-3 layers (sheets are much larger). Use contact cement to adhere them. Much easier, you aren’t poking and grabbing an imperfect layer and the foam is much better quality (it’s meant to be stepped on my fat 400 lbs dudes). Be honest, Kiezan foam is actually pretty crappy quality. Look at when you buy expensive tools and hand tools and you get them in a plastic case, they always have a more high density foam, like the HF, the cheap tools you buy or tools that don’t come in a case, come with crap foam, like Kaizan

[@stevequate1797]

Sorry like I’m not able to afford a layer cutter just to cut out 7 tools pockets fit my pack out, I’m not a rich boy or silver spoon in my mouth. Plus I don’t even have a laptop Cant afford one on my retirement money. Wished I could sure would make a nice cut but I bet I couldn’t find anyone to cut me out some at a affordable price everybody wants to fuck everyone. What had happened to just flat out helping people any more I don’t charge anyone for anything nearly guess that’s why I’m Anastasia broke

[@shamolshahran1570]

It's too complicated for diy.

[@davidanderson6385]

🇺🇸👍👍👍💥💥💥👍👍👍🇺🇸

[@mp5ive424]

Get to the point . Bla Bla Bla

[@briannisbet3982]

Get to the point

[@bigbrother9531]

Blah blah blah

[@Shoptoolreviews]

My wife says that about me too! :) Thanks for watching.

[@thebigdoghimself]

Rocker sells large foam sheets at a decent price, i would get a kaisen knife set that comes with the special markers, cutters and a hole cutter. I will mention that foam looks cool but there ends up being a ton of wasted space.