Systainer Organization - foam for the OCD?

[Scorpion]

So I've been poking around looking for ways to organize my sustainers (Festools and a variety of other tools of both hand and such).  I built a tool box for a Sys4 and that was a good start but that was one of a dozen boxes that could be organized or organized differently.  I've looked at the Kaizen foam but it seems that members have had mixed results.  Based on the pictures it appears that it's difficult to get a clean finish in the foam when "plucked" after cutting.  I've seen some organizers us multiple sheets of 1/2-inch foam, glue them together, and cut with better results and a variety of insulation type materials.  Since I know I have OCD I've decided to ask if anyone else with my condition can make recommendations before I buy a couple sheets and waste a day. 

 

[sae]

I think the Fastcap Kaizen foam is still a very good option. If you're OCD, you can use a hotwire and make much cleaner cuts. Use the 20mm instead of the 57mm and stack instead of digging out the foam.

In the end, when the tools are in place, you can't see what's under it...so the uneven digging doesn't really bother me.

 

[wow]

The Kaizen foam can be machined with good results. If you don't have a mill or CNC - I don't - you can use a router with a jig to cut out round, square, and rectangular holes. You can also use the LR32 base on a rail to make straight lines, i.e. spots for clamps.

I haven't tried using a hot wire yet, but I suspect I am not skilled enough to make it look much better than the 'pluck it out' method.

 

[elfick]

If you have trouble getting a clean bottom, it is usually fairly easy to cut an extra layer deep, separate the top layer you've removed, and push that down to be your bottom layer. You can glue it down if it seems loose.

 

[Scorpion]

I think the Fastcap Kaizen foam is still a very good option. If you're OCD, you can use a hotwire and make much cleaner cuts. Use the 20mm instead of the 57mm and stack instead of digging out the foam.

I've seen the Hotwire approach but haven't done a lot of research on building one and the little I have done indicates it's a hundred or so to do it right.  Anyone have info/links on DIY low cost version using around the shop parts?

The Kaizen foam can be machined with good results...

Really?  That's kinda neat.  I had not idea it was firm enough.  I'll give it a try in the mill and see what kind of finish (can I say finish and foam in the same sentence?) I can get.  For my setup this would be a great option if it works.

If you have trouble getting a clean bottom, it is usually fairly easy to cut an extra layer deep, separate the top layer you've removed, and push that down to be your bottom layer. You can glue it down if it seems loose.

I hadn't thought of that but really like that idea.  Could also completely thru-cut the hole and flip the negative as long as its symmetrical.