If I custom order some Battlefoam trays - one for Imperial and one for Rebel ships - what thicknesses would I need to order them for to account for the height of the models? This is for a BF Sword Bag.

I made a custom too and put 1.5 inchs plus add at extra 1/4 inch for the bottom. I did suggest in the comments that if possible to measure if I had the right thickness to use a ffg x wing model if they had one. Since the lambda is pretty high when laying on its side. I told them to change if necessary and if they had any questions to contact me through email.

For Rebs you can use 1.5" foam and for Imps you can use 2" foam. Also remember to account for the .25" layer on the bottom of the tray.

Awesome. THANKS. I will have the +0.25" in mind, although the Sword Bag is (IIRC) 11" tall, so even with a third "junk drawer tray" for all the bits and bobbles, it'll be another wave or two before it's full.

The only ship that requires a 2" deep tray is the Lambda. If you don't have a Lambda, you can get away with a 1.5" tray.

in 1.5" foam also you can triple stack Ys double stack A's. interceptors can be double stacked, Ties can be arranged in a rectangular slot. . X wings sit perfectly vertical if you cut a small square in the backing foam.