Router Bit Storage
I constantly struggled with loose router bits, shoddy storage pieces made from 2x4s, and trying to store different sized shanks in the same area. Eventually I decided to try running this Kaizen foam through my table saw to see how it cut. Turns out, it cuts perfectly! So I was able to store every bit I had in this section of foam I had laying around. A full 2x4’ sheet costs around $35, but you’ll only need a fraction of that to store probably more bits than you’ll ever own. Read on to see how to make your own versatile router bit storage.
Tools Required
Its a pretty simple project. But you will need a couple tools. The fanciest tool you’ll need is a table saw. Doesn’t have to be a good table saw. Just any saw with a fence. After that, all you’ll need is a tape measure, a straight edge, and good box knife or even a sharp kitchen knife.
Materials used
The only material I used here is Kaizen foam. It is by far the best tool foam I have found. It is actually layered every 1/8”, so you can cut down to any depth and remove the foam with your fingers to get a nice flat bottom (with a little practice). I used the 2” foam in this build, but you don’t necessarily have to go that thick. I’ll include an Amazon link to several different thicknesses.
Measure your drawer
Step one is pretty simple. Just measure the size foam you need with a tape measure. Since my foam was going in tool drawer, I just measured the size of my drawer. You don’t have to be surgically accurate here. Its foam, so it’ll compress some if you cut a tad bit large. Or if your cuts aren’t a perfect 90 degrees.
Cut the foam
I found the long box knives work best. I use a dewalt one, but any that has a 3”+ blade will work great. The easiest way to make the most accurate cuts is to make your marks and line up a straight edge. Then just guide your knife along the straight edge, trying to hold a perfect 90 degrees the best you can. Once its cut, I recommend doing a test fit before moving on to the next step.
Cutting the grid
Once you have the piece cut to size, its time to cut the grid. This is probably easier than you think. I used my table saw and a full kerf (1/8”) flat top saw blade. The flat top blade isn’t totally necessary, but I do recommend using a full kerf blade vs a thin kerf blade.
I make the first cut with my fence set one inch from the blade. Then rotate the piece 90 degrees and make another cut. I do this until all four sides have a cut 1” from the edge.
Once you have your piece looking like the photo above, you know you’re on the right track and the rest is easy. From here you just move your fence over 1”, make all four cuts again, then just continue making your cuts and moving the fence over 1” until you have a completed grid. When its done it will look like this:
Put it in its home!
I made this grid to go in my rolling tool chest drawer, but it would definitely function well as a stand alone unit. All you’d need is to build a box, or even just glue it to a piece of plywood. If you opt for the plywood, I’d probably make my first cut 2” from the edge, to avoid any bits falling out.
I originally designed this to be used for only my large router bits, however I quickly discovered it works well for 1/4” shank bits, die grinder bits, power carving burrs, even tiny Dremel bits will fit in this grid.
