Adam Savage uses foamcore to defeat workshop organization paralysis

Tools and Materials Needed

• Foamcore board: Standard 3/16 inch thick material works best.
• Hot glue gun: High-temp glue provides the necessary structural bond.
• Utility knife: A fresh blade is critical for clean, snag-free cuts.
• Straight edge: For marking and guiding long cuts.
• Pencil: To layout dimensions before applying glue.

Step-by-Step Assembly

1. Group your items: Gather tools with disparate form factors, such as medical hemostat or long-handled boroscope. Identifying what belongs together is the first step toward efficiency.
2. Layout and marking: Arrange the tools on a base sheet of foamcore. Use a pencil to mark the footprint and any internal dividers.
3. Construct the perimeter: Cut side walls and secure them with hot glue. Rubbing the glue immediately if it hits your skin can prevent burns.
4. Create internal standoffs: For long tools, glue small foamcore blocks to act as guides or elevators. This prevents items from shifting and makes them easier to grab.
5. Reinforce and label: Apply extra beads of glue to interior corners for strength. Add a clear label to the exterior for quick identification on a high shelf.

Tips and Troubleshooting

Don't let the perfect be the enemy of the done. Foamcore is forgiving; if a layout doesn't work, cut it out and re-glue. While often seen as temporary, a well-buttressed foamcore box can last for years in a workshop environment. If the box feels flimsy, add a second layer of material to the base or main walls to increase rigidity.

Conclusion

Using foamcore allows you to test a storage concept before committing to expensive plywood. You gain an organized workspace immediately, and the tactile experience of a "first pass" build often reveals better engineering solutions than a digital model ever could.