I am moving into some systainers using minicell. I failed at hollowing-out thick blocks of this material but succeeded at slicing complicated shapes completely through. I like to line the bottom with 1/4 inch, then cutout shapes from a thick block (1", 2", or 3") and put in a layer of tools.
I like the firmness of this material and also use it because I keep a lot of it around. I find I don't need shock padding like you might expect from softer foam. I need the items to pack into a systainer without hitting against each other. I have been able to get a lot of router attachments to fit into a sys2 and still have space. I get minicell from
www.noc.com under outfitting and repair. The 1/4" can form the bottom layer, and the next layer can be thick, with cutouts. The parts or tools can stick in only halfway down in some cases. The foam is very firm so heavy parts will not move.
I'm also moving into some maxisystainers. This has been more difficult- because of the tricky curved area from the carrying handle.
It's worth the trouble to put as much as I can in systainers. In my case, it brings the tools closer to me and packs into a vehicle better too. I would be able to assemble a 4 1/2 foot tall systainer stack onto the Festool rollers on a handtruck jig so I could take it up steps and roll it off and go for the next stak.
