Custom box insert help?

[jmbaker79]

So I need to custom make an insert for a box to hold a large diameter pen. The box I have is about 5" deep. I have seen the router route yet I want this pen near the top so it isn't like trying to pull a rabbit out of a hat. My question is what sort of material I should use to fill up the majority of the box, that can be shaped to accommodate the pen, and half circles on the sides for easy pick up of the pen. First thing that comes to mind is foam covered with black felt. Green foam I think would be too soft, and who knows what it would look like after the pen was picked up a few times. Styrofoam would be much more rigid, yet still impressionable and would sound terrible if ever pushed on for God knows what reason. Just looking for experience from those that have custom made boxes for individual pens. Thanks in advance for taking the time reading these novels that I have posted lately.

 

[randywa]

I used several layers of these foam sheets. I was able to cut each layer to fit the pens before I glued them together and covered with velvet. The foam isn't rigid so I thought it felt better than styrofoam.
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[jmbaker79]

Randy looks like a link there but can't view it for some reason.... Anyhow assuming craft foam is what you mean that would work great... Thanks! Open to other suggestions but this may be the ticket!

 

[snyiper]

Could use Balsa and flock it any color you like.

 

[randywa]

Randy looks like a link there but can't view it for some reason.... Anyhow assuming craft foam is what you mean that would work great... Thanks! Open to other suggestions but this may be the ticket!

I still can't load the link, but it was for EVA foam sheets at Hobby Lobby. It was 12 sheets for $5.99 and I have 11 sheets left. It's only about 1/8" thick. I think this is the same stuff someone had a thread about applying CA with and it works great for that too. Also used a few strips on the bottom of coasters.