foamcore

Prototyping Your Shop Storage Many makers stall on organization projects because they fear committing to a permanent design. Adam Savage solves this by using foamcore as a physical CAD system. This guide demonstrates how to build a custom storage tray for oddly shaped tools, ensuring every item is retrievable and visible without the stress of woodworking. 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 hemostats or long-handled boroscopes. 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.