How bout that plastic board they use for signs?  I forget the trade name,
but I have a friend who made a bike carrying box from it to travel on trains
with his bike...It looks like cardboard except it it a plastic and
cleanable, weather resistang (some campaign signs are printed on the stuff)
and you can cut it with a utility knife.  Plenty durable and very
light..washable and you can make egg carton stuff with it or use colored
duct tape to create any shape you want.  They also sell some kind of
fasteners and hinges that are made specifically for that material..Comes in
different strengths, thicknesses and sizes and colors.

  That would work..Maybe Google 'sign board' or composite materials or
plastic sheets...

   I just use cardboard boxes myself, and those gym bags and duffels.  Boxes
for the spare parts that need to be confined, then soft bags around them..

  Don Hanson

On Sun, Oct 10, 2010 at 7:25 PM, Mark Hineline
<hineline@ocotillofield.net>wrote:

> Pelican padded case dividers* are an obvious way to keep things quiet,
> organized, and safe under the Westy back seat. But they are absurdly
> expensive. Obvious DIY project. But before I start it, has anyone done
> this? Or does anyone know of something cheaper than Pelican that's
> just the same (not plywood or cardboard).
>
> Mark
>
> *
> http://www.pelican.com/oem/customize/protection_systems/padded_divider.php
>