Pics of working on the spare tire tool tray. I bought a 2’ x 4’ Kaizen Foam that was 2-1/4” thick. I actually bought two just in case, and after I cut the first one trying to fill the whole trunk I realized I would have been better off using the two long way and splitting it in the middle. It would have been SO much cleaner than how this turned out, but it was too late once I realized this. However, once the lid is on, you don’t see the mess in the very back, so no big deal.
For the initial shape, I simply used the cardboard box the foam cane in to create a template to know where the notches needed to be.
For the tool slots, I simply traced the tools and used a utility knife to cut down into the foam layers and peeled the foam out. You want it to be snug, so it takes a little trial and error to get them right, but super easy to do.
