Up to 1,000 in a 3800 case, but extremely tight! You have to cut boarder foam to make it work unless you can find the awesome Racks that
@joeyshin has which are 4 rows of 25 chips with lids as opposed to our standard 5 rows of 20 chip racks. Also love that this system stores the chips In a vertical arrangement (many discussions in the past about chip warpage being caused by chips laying horizontally...any truth in it? Definitely possible)
A standard 800 layout in a 3800 would be 2 high with 3 racks left to right and one row top to bottom as shown here
No idea where all these supposed "800 chips are tight in a 3800 case" came from but that is an absolutely FALSE statement.
To fit 1,000 chips cut the left and right side foam down to 50% thickness and add another row of chips to the right. Then it is tight. As shown
This is only 900 chips so you can see the edge of the yellow $20s is not sitting perfectly flat. It is only resting on soft roam below. For odd # racks your can add a number of products like thin wood, lexan, fiberglass sheeting to lay on top of the soft foam and keep the rack positioned properly. Unfortunately for this set I have 2 - 20 chip tunes holding my spares and hundos under that final rack on the right, so I have not added a stable floor for that rack, it requires a lot of qdditonal cutting with the tube below and just haven't gotten around to it.
If you are planning on going 4800 for 800 chips I hope you are also planning to pack, over night clothes. 4 pistols, 2 tacobell party 12 packs and a case of beer... because your chips are going to look lost in that huge case!