How to cut tool control foam. A step by step guide for cutting tool foam and the individual tool cut outs within your foam

Doing your own tool control foam cut outs may seem intimidating, although it shouldn’t be. We have prepared these instructions to help you cut your tool foam. You’ll be cutting tool foam like a pro in no time if you follow these instructions!

You will need the following tools: straight edge, tape measure, heat gun, utility knife. Optional tools that will make the process of cutting tool control foam faster include: plunge router, circular saw, hot knife, and carpenters square.

Step one: Take your measurements of your toolbox or workbench that you would like the tool foam to fit on or in. The goal is to not have space on the sides so measure to within 1/8”. 

Step two: Cut your tool control foam to the drawer size. You have three choices:

1)      The first is using your straight edge or square you can cut a template out of cardboard, plexiglass, or some other easy to work with material. Drill a hole in it and use a pin or other noninvasive item to hold the template in place while you cut the tool foam to your drawer size.

2)      Your second choice is to mark the tool foam with your desired drawer size and using your circular saw with guide cut a straight line. This is really only feasible if you have a good work surface. If your work surface is the ground, go with #1 or #3.

3)      Your third choice is to mark the tool foam with your desired drawer size and using your utility knife or hot knife cut a straight line with your straight edge or square aiding you in keeping the drawer square. 

Step three: You can cut your shapes out in a couple different ways, its up to you as what works best for you.

1)      You can use a sharpie and trace the tools on the tool control foam in their desired locations, once in their location use the hot knife, plunge router or utility knife to cut out the tools shape.

2)      You can use tracing paper to trace the tools, once traced you may lay the paper on the foam drawer, secure with tape, and cut through the paper and foam using your utility knife or hot knife. 

Step four: You will need to laminate the tool foam ½” layer onto the ¼” layer with no cut outs. You will want to practice on some scrap foam first. Heat the foam with the heat gun until it is tacky. Once tacky, quickly place against another piece of foam and hold momentarily. Within seconds the foam will be bonded. The principle is the same for laminating drawers only in this case you will be placing the top layer on the bottom layer and starting at one side heating up the foam in a sweeping motion from side to side while applying pressure to the top layer of foam creating a “sandwich” effect on the foam. Continue until you have laminated the drawer from side to side, apply pressure as you heat the top layer and smooth on the bottom.  

Step five: Place the tool foam in your drawer or in your tool control kit and insert tools. Your tool foam is now ready to use.