Have you had to chose between buying that totally awesome custom foam bag, or getting those few extra units that you couldn't compete without? Have you ever said to yourself, geez there must be a way to do both, that's quick and inexpensive! We'll you're right, in this article I will teach you how to make your own custom foam trays.
Time Required:10-15 Minutes per tray
Difficulty Level: Super Easy (If you can assembly minis you can do this)
Tools you will need:Scissors
X-Acto Knife
Wood Glue/PVA Glue
Materials:Foam Board
Cushion Foam
Traveling case(s)
Cost:$3 per sheet of Foam Board (Enough to make 2-3 trays)
2"-3" Cushion Foam (10 per yard)*
Travelling Case ($22/$
Total Cost: 4 trays (2x 2", 2x 3") + case for $48
Step 1) Gather the materials. Foam board can be found in most arts and crafts stores, buy the largest sheet you can find. Cushion foam can be found at most fabric stores, or you can get it from people who are tossing away old couches. If you do decided to go the cheaper route, double and triple check that there are no bed bugs. Finally you can get a travelling case with wheels from most office supply stores for $22. Ask for the Folding File cart, which is the perfect size and comes with wheels. Or you can get any old plastic tub. (Maybe you've got one at home. )
Step 2) Measure and cut the foam board & cushion to fit the inside of your container.
Step 3) Apply wood glue liberally to one side of the foam core.
Then use your finger or a piece of scrap to make sure that the entire underside of the foam core.
NOTE: Make sure to get the glue right to the edge of the foam core.
Step 4) Attach the foam cushion to the foam core
Step 5) Apply a weight to the top of the foam equally distributed across it.
This is very important! If you fail to do this, you will have a warped tray!
Step 6) Add minis! Using a marker, trace around your minis.
Step 7) Then cutout the outline with a sharp X-acto knife.
Tip: You may need to pull the foam away from the side wall to cut it.
Step Test fit mini, adjust the sides accordingly
Step 9) Optional. For some of the larger heavier minis you might want to put some foam over them. Just invert the cutout foam and insert it into the mini tray to determine how deep to make the cut.
Then cut down the top, and add a name.
