Pelican 1535 Air Tool Foam Kit (Set of 4 Black Foam Inserts, 3 Red Plastic Backers & One Red Bottom Foam)

This DIY foam set is specifically engineered to transform your Pelican 1535 Air carry-on into a professional-grade mobile tool case. Whether you're a technician on the move or a hobbyist who appreciates "a place for everything," this kit provides the structure and visibility you need.

Foam Kit Features:

• Custom-Tailored Fit: Every piece is precision die-cut to match the Pelican 1535 Air interior, featuring rounded corners, hand-hole cutouts, and wheel cutouts for a seamless drop-in experience.
• High-Visibility Shadowing: The dual-color system (Black foam over Red ABS plastic) creates an instant "shadow" effect. If a tool is missing, you’ll know immediately thanks to the bright red background.
• Superior Durability: We use 2lb black cross-linked polyethylene foam. It’s tough, professional, and designed to withstand the rigors of travel.
• Rigid Construction: The red ABS plastic sheets don't just add color—they provide a rock-solid backing for each foam layer, ensuring your tool trays remain stiff and easy to lift.

Foam Kit Specs:

• Compatibility: Designed exclusively for the Pelican 1535 Air Case (Case not included).
• Total Weight: 3.5 lbs.
• Material: 2lb Black Cross-linked Polyethylene Foam & Red ABS Plastic.
• Included Components:
  • Bottom Layer: 1 Black stay-in-place foam (2.00") + 1 Red shadow foam (0.125").
  • Removable Trays: 2 Black foam pieces with adhesive backing (1.00") + 1 Top black foam piece with adhesive backing (1.375").
  • Structural Support: 3 Red ABS plastic sheets (0.125" thick) for lamination and shadowing.
  • Lid Protection: 1 Convoluted "egg-crate" lid foam (1.75").

Instructions:

1. Trace: Lay out your tools on the black foam layers. Once you’re happy with the organization, carefully trace each tool.
2. Cut: Use a utility knife with a fresh, sharp blade. Foam is notorious for dulling blades; don't be afraid to snap off the tip or swap blades frequently. Use multiple shallow passes rather than trying to cut through the entire depth at once.
3. Laminate: Once your tool shapes are cut, peel the adhesive backing from the foam. Carefully align and press the foam onto the red ABS plastic sheet.
4. Set & Secure: Apply firm pressure across the entire surface to ensure a permanent bond. Repeat for all removable layers.
   Note: The thick bottom foam piece is designed to stay in place and does not require adhesive lamination to the thin red bottom foam.