I don’t think my foam was quite as rigid as yours
I used the Amana 51404-k bit and it produced pretty nice cuts. This foam was in layers with glue between so you could in theory cut the perimeter and then peel up the layers to the depth you desired. In practice it didn’t peel that well so I just cut pockets to the depth I wanted. Only issue was when one of the pockets was at the exact depth of a glue layer. It was a little messy then, other than that the bottom and the top cut cleanly.
A further consideration on this sort of thing is that there is a specialty tool for cleaning up the bottoms of pockets:
Yeah this is some pretty dense EVA foam. What you are describing is Kaizen foam (or a knock off), which to me is way more expensive than it should be. The 7 dollar Harbor Freight knee pads are a fantastic value and hold onto my tools really well.
Actually what I bought wasn’t too bad. $21 for a 4x2 sheet: https://www.rockler.com/rockler-foam-organizer-sheet
My drawer is the full width of the table that my Pro 4x4 sits on.
I would have had to buy 4 of the ones from harbor freight to cover that but looks like a great solution for smaller drawers.
I will check it out because I want to go to HF anyway to get a rolling stool for bit changes to save my knees.
I’m definitely going to use some of this info as I fit out drawers in some new assembly tables I’m building after my shop is expanded. thanks for the links.
And thanks for the reference to Winston’s video - you know, foolish me, I’ve been lugging around my ketchup packets without any protection…never again. 
An electric turkey carving knife work’s excellent on foam, while not the tool for cutting out notches works great on sheets.
Damn. When I checked Rockler was completely out and it looked like the discontinued the product. Of course a week later and its back in stock.
Still knowing how to cut EVA foam will come in handy the next time a friend needs Cosplay armor.
I need to check out the HF foam I’m always there ha. I did order and cut foam from foamfittools.com and it went pretty smooth with an Amana foam bit #46564 1/8 need a 1/4 bit now.
Yes, I bought mine several months ago and the next time I looked it showed out of stock. Then popped back up recently.
What do u guys do if u wanted to cut out slots for wrenches. How would you measure it so it cuts the specific tool dimensions?
See:
I kind of figured that
I might just lay out the tools, trace them and use a foam cutter n my palm router to see how that works.
Would it be possible to do this with the Nomad that only goes up to 10,000 RPM?
I copied them and imported and traced. I would be happy to share my C2D file if you want. Your wrenches may be different though.
My file also has a nice cutout for the SST mini tramming gauge. That one was a good bit of work.
EDIT: Added the files. It is broken into two as my foam was 48" wide. The most interesting stuff is in part 1. Overall there is a spot for a tape measure, square, tramming gauge, 2 wrenches, cam clamps and angles, three allen wrenches, lots of bits and collets. There are some random pockets as well.
I always find myself using the wrenches the other way and have to flip them around for storage every time.
FoamFullPart1.c2d (336 KB)
FoamFullPart2.c2d (280 KB)
Sure!
See:
I am wanting to do a whole tool Box and a extra drawer for my CNC tools but everything I have found doesn’t seem feasible. I think I will trace the tools and use my palm router with a foam bit.
It isnt that hard in Fusion360. Put your tool on something with a high contrast background. For instance my shiny Dewalt collet wrench I put on a sheet of black paper. Take a picture from above. Bring it into Fusion360 as a canvas. Take a physical measurement off the real thing. Scale the same section in the canvas to match. Then use the sketch tools to sketch the outline and add any additional features.
I tried it on white paper but there were shadows messing everything up. I will try it on black. Thanks
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