I took the advice of the Rev (from a different forum but same beloved Rev) and bought a workout pad from Walmart to make inserts for fly boxes. It is a closed cell foam (like neoprene) and not quite as good as the blue foam in the Cliff boxes, but plenty good for holding flies. For 20 bucks I got enough to make all the fly boxes I will ever need. Cut it to shape, glue it in, use a razor blade to cut slits,,,,,and bingo...instant fly box. I used the little plastic soap boxes with hinged lids to make a couple pocket sized boxes to hold my Sandbass flies...It will hold a season's worth of Moreau flies or Neked Ladies. I think the little boxes cost me around 50 cents at Walmart. Also, check out hobby lobby or Michael's for a box made by ArtBin. It is the same shape and design as the Bugger Barn.....about 6 bucks....glue in the foam....you get the idea.
And of course my personal favorite...the VHS tape box.

What a fine idea! Better get on down to Goodwill and snag as many of those VHS boxes as you can, they are going, actually already gone, the way of the dodo bird.

Two words: "Snus tins." They are the perfect pocket size, but of limited value for poppers and other overgrown flies. Great for wooley buggers, nymphs, my ever increasing assortment of trout flies, and generally any size 6 or so and smaller fly. I do realize some of you have never seen a size 6 fly, but they do exist.

Most of these are size 2 or larger.....but you could fit a LOT of smaller flies in one of these babies...

Budd I will have to look for the work out pad you mentioned one of these days. I thought they were all a bit thick for a fly box, but I will see what you are talking about. I have several VHS boxes and tie foam in exactly as you do in the picture. They make an alright box...nothing fancy at all, and they are cheap. Now I heard about using Plano pistol cases for a fly box, and they are about 6 bucks at Academy. You have a sturdy case there. Take out the foam for the pistol, and put in your own foam in it's place. I sent off for boat patches from Millcreek or something like that. That is a cheap way to go for a box that should be long lasting, and it will make a great BOAT FLY BOX. It will be too much to put in your vest though. If you keep one box with bigger flies...that would work great. My foam inserts were back ordered wouldn't you know. So when it gets here, I will put in Slumpbusters, and EP baitfish patterns, and the bigger streamers. I wouldn't think it would be real good for small flies, but who knows. You could make a magnet area and glue that in too for the small flies if you wanted to. This box would also be perfect for poppers and sliders that are bass sized. Just a thought. (oh I also use pencil boxes like they clear out after school starts every year...they are a little wide though for your vest...I keep these type in a tackle type bag.

+1 on the Snus tins. They are perfect for trout flies and for a quick trip to the pond for a few gills.

I use vhs boxes for big flies.....I carry a shoulder bag or use a boat bag....I quit using a vest years ago...Just like the bag better. Now as for the snoose cans....is that copenhagen or skoal? Which flavor do they prefer.

By the way...I bought my shoulder bag at Army/Navy surplus. 8 bucks.

Here is my soap box fly box


Found this at Michaels. I am making my own Bugger Barn..


My favorite shoulder bag

For ready made slit foam inserts at a decent cost...

http://www.bearsden.com/page815.html

The EP flies hold their shape better when they are stored flat. Like a little zip lock bag. I found a "worm wallet" at walmart that has a nylon cover and 8 large zip lock envelopes. Under 10 bucks. I use one for keeping my shooting heads...the other for storing EP flies. Again...I carry a bag....no vest. So plenty of room for it.

Bud,

you can get sheets of 6mm thick foam from Michael's as well... goes into your flambeau case which in your photos is called "art bin". I have made a few boat boxes with the stuff.

Funny you should mention that...I came across some today.

I use Falcon FTO boxes, get 'em at Academy , http://falconrods.com/index.php/tackle-organizers/fto-boxes/fto-300.html

Note: the dividers on these boxes lift right out

these are all good ideas for future boxes...