DIY Mini Case - Twice the Space, Half the Cash!

[Gr33nJ3llo]

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/$8)

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.

[Gr33nJ3llo]

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!

[Gr33nJ3llo]

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 8) Test fit mini, adjust the sides accordingly

[Gr33nJ3llo]

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.

[PG_Agamemnon]

I did something similar to this for my paints. it works very well.

[2LiveIs2Die]

I was planning on doing this with much thicker foam when i get 2 wraith engines together. I will use a shoe box or something and put terminus and both engines in it

[Gr33nJ3llo]

I was planning on doing this with much thicker foam when i get 2 wraith engines together. I will use a shoe box or something and put terminus and both engines in it

Thickest I've seen is 4", you might have luck gluing multiple layers of foam together. I did it with some 2", and it worked pretty well.

[CyberKnight]

I use the same foam but I don't bother with the bottom board. For larger models, I'll store them flat instead of upright. When I cut the foam, I just leave a reasonable amount underneath when I hollow out the hole for the mini. An occasional pose wont work well for this method, I reserve those for the top layer of foam, and have a thin piece that goes over top.

[Peg leg Pete]

since you brought it up on another thread, and i don't want to hijack that thread, i'll ask here: those folding file carts look like a decet size, but i have two questions:

1) how many figures can you hold in each one

2) can you buy extra carts to place on top for additional storage?

[Gr33nJ3llo]

since you brought it up on another thread, and i don't want to hijack that thread, i'll ask here: those folding file carts look like a decet size, but i have two questions:

1) how many figures can you hold in each one

Honestly, I don't have a good answer for that, since it really depends on the figures. The trays are 15"x12", which is almost twice the size of the battlefoam stuff. As a complete random guess I'd say around 30-50 figures. My most filled out tray is for Cygnar, which holds:
Complete SB + UA
Complete ATGM + the Dude
Min Trenchers
Max Long Gunners
31

With room for another 10-15 guys.

I've also got a half full mercs tray with 20 Risen + Alexia + 3 Thrall Warriors + Max Steelheads + A & Holt, which is another 33 or so?

I've got 5 layers in that one, holding Jacks w/ 3", and every thing else with 2" + room for books, tape measure, etc.

My trolls take up much more space naturally.

2) can you buy extra carts to place on top for additional storage?

Haven't needed too yet, though the Collosals + Terminus has me thinking about it. For something like that you could add another plastic box, and bungie it to the top:
http://www.officemax.com/office-furn...ct-prod2550256

[captainspud]

I've been doing my trays this way for years. Completely agreed on the cost and space benefits.

Differences in process/materials, out of interest:

1. I cut out sheets of MDF instead of using foamcore. More annoying to make, but sturdier.
2. I use 5-minute epoxy instead of wood glue because I'm impatient. :P
3. I only put glue on the outside edge of the foam, not in the center. I find it's much easier to pull the plugs out cleanly when they're not glued from the bottom.

But, yeah. Regardless of the specifics, I definitely recommend people make their own foam and cases. You can buy awesome fancy boxes at decorating stores like HomeSense for like $15-20, far less than any of the dedicated carry bags.

[PG_Agamemnon]

I use one of those rolling carts for my main army. People asked me so often how much fit in there that I posted this. Sorry for the link instead of posting the pic... it is a link to this forum so I dont feel bad.

Here

I have changed out a few trays in the last couple of months to Sabols precut. They hold a few more troops that the pluck foam... something I needed pretty disparately.

[Gr33nJ3llo]

I only put glue on the outside edge of the foam, not in the center. I find it's much easier to pull the plugs out cleanly when they're not glued from the bottom.

I did that with a few of my original trays, and switched over to making sure the whole surface is coated. You are correct it makes it harder to pull out the foam, but the trade-off is having the foam between the models not move. I usually cut some pretty tight holes, resulting in less that 1/4" between models.

[baronvonchaos]

For the bag, I'm piecing together a leather transport bag. A buddy of mine does leatherworking and it's about $15 for the supplies (not including tools) and you can make it as deep and wide as you want. I had some ideas about the foam, but this is far easier. I'll have to do this for the foam. My gun case just isn't cutting it with all the merc troops I need. Then I need 3 more bags for my Trolls, Khador/Cygnar (small forces), and Menoth. Especially with the advent of Colossals. They won't fit at all in my gun case I use now .

[PG_TimVanBoening]

I like this idea!! My Battle Foam case is full to the gills. I may have to do this for my (ever expanding) Trolls, especially the Mountain King.

[PG_Drifter083]

I have a very similar tray for battle engines and collosals. its four 2inch foam trays stacked to give me depth inside a hard case. works a treat.

[Bronze Knight]

For the bag, I'm piecing together a leather transport bag. A buddy of mine does leatherworking and it's about $15 for the supplies (not including tools) and you can make it as deep and wide as you want. I had some ideas about the foam, but this is far easier. I'll have to do this for the foam. My gun case just isn't cutting it with all the merc troops I need. Then I need 3 more bags for my Trolls, Khador/Cygnar (small forces), and Menoth. Especially with the advent of Colossals. They won't fit at all in my gun case I use now .

You just need more guns. Then you can justify getting a bigger gun case.

[SpecialK]

Unfortunately for me, the only foam and foam-board I could find in my area was super-expensive. I already bought the rolling/folding crate (which still seems good), so I just bought some pluck Battlefoam from the LGS to stick in there. Oh bother.