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Box Inserts/Cradles

1237 Views 5 Replies 6 Participants Last post by  sunnybob
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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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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.
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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