Fly box and inserts system...

[FishnPhil]

Finally found the time to finish this project. I still have to add a lot of my flies to the inserts but I figured now is a good time to post pics and info so if someone else likes this or anything they could do it before the summer starts.

After deciding I needed a better way to organize my flies I thought of ways to make inserts that would fit into the front pocket of my fishpond chestpack. That way I could swap out inserts based on hatches, rivers, time of year, etc. Along with that I would need fly boxes to hold the inserts because my chest pack only holds one. Which then made me think I would need a bigger case to hold the inserts I'm not using at that time.
I found the C&F system and Scientific Anglers System X online but both were very expensive, 6 inserts, plus the case and three fly boxes would have cost me $200. So I set out to do it much much cheaper (and my inserts are much bigger than the C&F ones).


So here's the pics and how I did it.......
I found foam door hangers at Hobby Lobby. The foam matched exactly in thickness and density with the foam I already had in my fishpond pack. So I cut them out to match in size, basing the size from the first one that I have:
http://i208.photobucket.com/albums/b...m/P3180001.jpg
http://i208.photobucket.com/albums/b...m/P3180002.jpg

Then for some of them I used a box cutter to cut out the "slats" for fly hooks to be inserted into. I also left some just whole because I seem to like those for certain flies too.
http://i208.photobucket.com/albums/b...m/P3180004.jpg

As you can see it's all up to you what size and shape you make the cut-outs. The white one it working great for my streamers and wooly buggers.

Once I cut out the pieces I started looking for something to back them up with for support. It had to be thin, a little flexible but not too much, and cheap. To my astonishment this is what worked best:

http://i208.photobucket.com/albums/b...m/P3180005.jpg
I found a good use for these signs after all

Cut out a piece to fit the foam and used gorilla glue to bond them together:
http://i208.photobucket.com/albums/b...m/P3180007.jpg

Once the glue dried I cut it out and placed 3 velcro strips on the back:
http://i208.photobucket.com/albums/b...m/P3180010.jpg
http://i208.photobucket.com/albums/b...m/P3180011.jpg
http://i208.photobucket.com/albums/b...m/P3180012.jpg
http://i208.photobucket.com/albums/b...m/P3180018.jpg
http://i208.photobucket.com/albums/b...m/P3180019.jpg

Inserts are now done once I repeated those steps a dozen times. Now I had to make the case and fly boxes.

I found this felt material with a sticky back for 59 cents a sheet at hobby lobby that attaches to velcro nicely:
http://i208.photobucket.com/albums/b...m/P3180003.jpg

Also found this clear case (8.99 I think) that I placed the felt material into:
http://i208.photobucket.com/albums/b...m/P3180013.jpg
http://i208.photobucket.com/albums/b...m/P3200024.jpg

The fly boxes I found at sportsmans warehouse for $4 each:
http://i208.photobucket.com/albums/b...m/P3180009.jpg
http://i208.photobucket.com/albums/b...m/P3180020.jpg

I ripped the foam out carefully, used a hair dryer to heat up the glue and make it easier, so that I could use that foam for other inserts too:
http://i208.photobucket.com/albums/b...m/P3180021.jpg

Placed the felt material into the fly boxes:
http://i208.photobucket.com/albums/b...m/P3180008.jpg
http://i208.photobucket.com/albums/b...m/P3200029.jpg
http://i208.photobucket.com/albums/b...m/P3200030.jpg

Done. Now all I had to do was start filling it up and making sure the the weight of the flies wouldn't be too much for the smaller strips of velcro. Worst case I might replace those later, but that will be easy.
Here's more pics:
http://i208.photobucket.com/albums/b...m/P3200027.jpg
http://i208.photobucket.com/albums/b...m/P3250034.jpg

I'll have to calculate the total cost, but I'm estimating less than $30-40 in materials.

Please feel free to comment, critic, post questions, or whatever

[garnede]

Great post.

[ADfields]

Looks great!

That’s cool, very easy to find them that way.

Thanks for going to the trouble to post it, you put a lot of work into this post also.

Andy

[fishnngrinn]

very creative, I love it. Thanks for sharing--great pics