Eyepiece case

I like to get some knowledgeable opinions about making up an eyepiece case. I'm sure all you guys with 50+ eyepiece collections have long since figured this out.

I have a large Dockucil case with the standard, open-cell foam "pluck" insert. Long-term I don't think the foam will hold up. As my eyepieces change so must the foam. I'm think of using the pink builders foam as a substitute. It's cheap, readily available, has different thicknesses, and easier to cut. I think it's poluyurethene based, but I'm not sure.

Does anyone know if outgassing is a problem? Is there a better substitute available that I'm overlooking?

Another issue. Is foam the best way to go? :S I've seen some cases that use cutouts to fit the barrel made of wood or lexan. Is this a better way to go?

Another question I thought of after looking at Floyd's cases. The case I have is very deep, any opinions on laying out the eyepieces vertically vs. horizontally? If horizontally, I can have two layers for the EPs.

Any pics that I can get ideas from is appeciated. Thanks in advance for your ideas and comments.

I have a bit of experience with foam and cases. I have found two types of foam to be the best. One is Polyethylene foam, a closed cell type that is quite firm. It does not dust and is easily cut as well as hold it's shape under high loads.
http://www.foambymail.com/Polyethylene.html
The other is a packing type foam used to make custom case for tools and instruments. It is easy to cut and does not dust but does leave a slight amount of debree on surfaces cut with a hole saw that can come off and they must be rubbed off before using. The big case in the picture uses this type foam
http://www.foambymail.com/packaging.html
I have used both now and they ar both quite good for this purpose and do not seem to out gas or have any smell or residue.
I am not sure abou the building foam however, I have never used it or seen it used.

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Try www.foamrubber.com. This a foam specialty store in Boston. They sell a product called "Ester Foam" which is used in camera cases. It comes in a variety of thicknesses and they will precut (case size) to order. I've had good success with soaking the foam, freezing it and then cutting the eyepiece holes with a serrated knife.

I took a rather different approach:

http://www.astromart.com/forums/viewpost.asp?forum_post_id=375267&poll_id=&news_id=&page=