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Still busy making my first box using box joint corners. I'm replacing a crapppy, cheap wooden box that has housed a set of four Craftstman chisels, which are cradled in an insert with recesses for each chisel handle.


I want to make a replacement insert/cradle and am curious about how you guys have done this. I have some Ethafoam, which if carved out and covered with felt could make a nice insert. What I am interested in is how to carve/cut out the hemispherical recesses. They are all the same size, same as the handles, although the shaft recesses are a little different.

I've got several machines that can spin cutters and sanding discs, but not in the sort of path that these cutouts need to be.

Thanks in advance,

Rick
 

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Theo
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How I would do it, get a strip of wood, put in holes/slots, then fasten it someplace handy, maybe the wall, maybe on the inside of a cabinet door. Or, just use a pouch, with separate chisel pockets. My personal favorite is the pouch, then lay them all out where you I quickly change chisels.
 
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You can also use a spray can of insulation. Spray it in and it conforms to the tool size as it expands. Nice snug form fit.
 

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Wrap the tools in plastic wrap before using the spray foam. That way you will still be able to use them.

I prefer to put a couple of layers of thin semi-rigid foam sheet down. Then trace around the tools on the top layer; cut out inside the lines; glue the two sheets together and put it in the box. Custom recesses for the tools.
 
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If you use the spray foam and the plastic wrap I would oil the tools really well first. Years ago I used some spray foam to seal the duct and wiring area of a range hood. A couple of years ago I replaced the fan with a new one and found that the spray foam had dissolved the outer plastic sheath on the loomex/romex wire. The inner conductors were okay but there was nothing left of the outer sheath.
 
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