your best bet would be these http://stores.cigarsolutions.com/-strse-141/Foam-Cigar-Tray-for/Detail.bok. you will need a LOT of them. 6 per layer, and looks like 5 to 6 layers deep. trays would need alight trimming.What are the dimentions of the foam inserts that he used. I just got gifted a used pelican 1600.