I am looking for recommendations on a good travel sized case that can be used to bring a couple squads to a gaming store, along with dice, templates, cards, etc.

I store my stuff in a BattleFoam PACK 720 and Plano 1374, but I really don't want to have to lug that all around. I'm looking for something smaller and more flexible, so I can swap out different ships based on what I'm bringing that day.

There are a ton of resources out there to research stuff online, but the good folks on this forum have a lot of direct experience, so I am looking forward to hearing what you all think.

Also, I have a hot wire cutter and quite a few foam sheets of various thicknesses @ 12" wide (bought them for doing my own custom PACK 720 layout), so I can make my own custom foam. So I don't necessarily need a pre-cut solution, since I can make my own inserts.

I built my own out of oak.
Dovetailed joins for the corner construction for the outer layer
The individual shelves of ship are built as sliders, tongue-in-groove construction.
Individual cradles to hold the ships into place are whittled to fit correctly, then socketed into the floor of their cells.

Rulebooks are kept in a false-bottom of the lid, so that they're available and upright while the box is open.
Weighs about 40 lbs when empty.

...I theorycraft while watching the Woodwright's shop.

I built my own out of oak.

Dovetailed joins for the corner construction for the outer layer

The individual shelves of ship are built as sliders, tongue-in-groove construction.

Individual cradles to hold the ships into place are whittled to fit correctly, then socketed into the floor of their cells.

Rulebooks are kept in a false-bottom of the lid, so that they're available and upright while the box is open.

Weighs about 40 lbs when empty.

...I theorycraft while watching the Woodwright's shop.

AWESOME, but I think I want something lighter and less labor intensive.

Individual cradles to hold the ships into place are whittled to fit correctly, then socketed into the floor of their cells..

Pictures please

In this for the info. I'm currently shopping for cases myself.

Here's what I have. It's not perfect, but it works well for me. I also like how portable it is. It's less than 13 bucks on amazon and I think it says something that the X Wing core set is an item shown as being frequently purchased with it. Obviously you wouldn't have to fill it as full as I do if you didn't want to

http://www.amazon.com/gp/product/B00005QWYF/ref=as_li_tl?ie=UTF8&camp=1789&creative=390957&creativeASIN=B00005QWYF&linkCode=as2&tag=boagamfor-20&linkId=2QU6KTKTE7NPWR6

The second case is just a generic one from a craft store so that I can fit a few more ships in.

I asked for a second case for Christmas so I have someone to put Scum ships and to spread things out.

The foam I used is old extra foam from Thunderstone that I cut down to fit. I'll probably add some foam for the shuttle soon.

I have both the yellow one shown previously and the clear top two layer plano.

Both of them are decent. The Plano fits a lot of things just slightly better but both work. The yellow has the added benefit of being able to pull out the little boxes. This can be really useful at tournaments.

http://www.containerstore.com/shop?productId=10032164&N=&Ntt=hobby+box

Either small (blue) or large (green) hobby container should fit your needs. The top tray should be able to fit your maneuver templates and all your neccessary markers/miscellany, and possibly even some cards. The main compartment should be able to hold all your ships and bases. Depending on what you are fitting and how many pegs, it will hold some of the ships on their stands all ready to go.

The green will hold some of the bigger fleets and ships, although I can't confirm if it will hold things like the YT in it.

Battlefoam trays and cardboard banker boxes. It's a tight fit, but it works.

I'd look at grabbing that foam and making up some generic sized trays so that you can mix and match a variety of ships. Just rectangles and squares that will accommodate a few options. These can be dual purpose to hold smaller collections, or to hold new ships until you cut a proper tray for them. 4" of foam should give you a reasonable selection and add in a 1" sheet to hold cards and tokens, etc and it will all fit into a PACK Plus. The PACK Plus can then be attached to the bottom of your 720 for when you want more storage.

I have a 720 and a Pack Plus and intend to make my own trays over Christmas and this is what I intend to do.

Edit: I intend to make a multi level tray that is actually made from 2 1" layers of foam. That way I should be able to fit in two big 2" holes (one Falcon/Decimator sized, the other Shuttle/BH sized), Some smaller 2" holes (TIE Fighter/Defender/B-Wing/Phantom) and then some 1" square (E-Wing/X-Wing/Z-95/A-Wing/etc) and rectangle (Y-Wing/HWK/Interceptor/Bomber/etc) holes.

2nd edit: Also good if you decide you want to fly somewhere and play X-Wing. Chuck your clothes and stuff in the 720 and your X-Wing in the PACK Plus. Zip them together and they'll be one bag for flying purposes but you can split them apart once you get to the hotel or wherever you're staying.

I used a plano 3700 recently.. I too store my stuff in a Battle foam 720.. I had some pluck foam left over that I squished around the ships to keep them from rattling around. it was a 4 ship build. 5 or 6 small ships are probably the most one 720 can handle and STILL carry EVERYTHING thats needed for a game... range rulers cards etc. The 720 also fits on top of my BF bag as well. As i normally use it just for my tokens, dice etc. its more space efficient than the battle foam. Particularly for items that don't require protection I don't think the 3700 will work for a Falcon unless you were to cut some of the plastic dividers and glue in your own. They are cheap though. Wallmart has them and Acadamy sports has a HUGE selection of similar products.. hmm was just browsing the Battle foam web page and will definitely be ordering a pack plus as my new travel bag for when i just want to carry a few ships for tournaments etc..

I bought a kr 1/2 size aluminium hard case. Looks the biz, and because the small ships are stored fully assembled, set up takes seconds. Enough space for a couple of squads, my 3d asteroids and all the gubbins.