|Project by mochasatin||posted 06-26-2016 08:21 PM||858 views||0 times favorited||6 comments|
Over the years, wrench sets and screw driver sets tend to break apart and pile up in the bottom of my toolbox. The original plastic packaging does not seem to last very long before breaking apart so I decided to come up with my own solution to the problem. What I needed was a general purpose solution that efficiently stored sets of slender tooling. I wanted to be able to store my tools in a small, custom box by tool size. Finally, the tools needed to be stored tightly and not rattle around. I ultimately came up with the solution of using small squares of anti-fatigue mat foam.
I tested a many different dimensions of the foam sizes, but settled on a simple 2×2 inch square piece. To start, I determine the rough dimensions of the box needed to contain the tool set. Since it is just a utility box, I use scrap wood and some old hinges. I then glued a stack of the 2×2 inch square pieces to the bottom of the box from one end to another like a loaf of bread (see pictures). The stack must be supported on both ends to maintain compression. After the glue is dry, press your tools into the slits and you are ready to go. You can adjust the compression by adding and extra square or two. With tight compression, you can hold a box full of wrenches upside down and shake it and nothing will move. Initially I tried making kerf cuts in long pieces of foam, but that did not work well because I could not control the compression and the tools did not seat as tightly as I liked.
I was very happy with the way the first utility box turned out for my wrench set. I am going to build several others for a screw driver set and a bunch of router bits. I thought I would share this project with others in case they found it useful too. You can easily scale the foam size to match your specific needs.