I don't know how helpful this will be, but I think I figured out what the various possible configurations were with all chip boxes going in the same way before I purchased my Pelican case. I didn't calculate what would happen if you had some chips stored more than one way as there are so many possible variations. I didn't figure out what the maximum number of racks would be.
Pelican 1510 Inside dimensions (inches) = 19.75"x11"x7.6"
Boxes = 6.625x3.625x1.75 (inches)
2 (6.5" left) x 3 (.125" left) x 4 (.6" left) -- 24 boxes @ 52.9 lbs of 10 gram chips
Boxes = 3.625x1.75x6.625
5 (1.625" left) x 6 (.5" left) x 1 (.875" left) -- 30 boxes @ 66.14 lbs of 10 gram chips
Boxes = 1.75x3.625x6.625**
11 (.5" left) x 3 (.125" left) x 1 (.875" left) -- 33 boxes @ 72.8 lbs of 10 gram chips
** Note that this configuration has the boxes standing in the case and will require 2 cases to stand above the top of the case and thus extend into the lid area.
So you can compare, 10 boxes of 10 gram chips weighs just over 22 lbs. Ten 5x20 racks would weigh the same.
The 1510 will hold a lot of chips and still allow room for at least some padding. The weight, along with the approximately 20 lbs for the case, plus whatever you carry, becomes the issue. I thought of all three of these, and believe even though there might not be a lot of foam padding left, with the case itself, the chips in boxes would be well protected. Chips are not that fragile unless you are going to be throwing this around against hard surfaces and deliberately trying to damage them.
If you want to know how much your chips would weigh, just multiply the weight of your chips in comparison to 10 gram chips.
I thought of cutting foam for 1,000 chips, 1,200 chips; 1,400 chips; 1,500 chips; 1,600 chips; and 1,800 chips using the 4x25 boxes. I think if you don't leave .5" of room in the cut area or between your chips and the inside of the case, they would be difficult but not impossible to remove, especially the deeper ones. I cut for 1,000 because they met most of my carry needs, and I could supplement the number of chips with a range bag (800-1,600 chips) without too much trouble and still be able to roll it all.
Obviously there are a lot of ways to use not just the 1510, but any other Pelican (and similar) case. Figure out what you want and/or need, and plan accordingly.
Codeman, if you want a Pelican-type case, you don't have to get one that is a foot deep. Many will hold 1,000 chips. Certainly you can separate your cash and tournament chips if you want to. I don't think it requires a lot of padding to keep chips pretty safe and secure. Unlike sensitive equipment or a scoped rifle, some jostling around won't cause your chips to fail or even get damaged. The two questions I think you need to ask are whether you want to be able to roll them and what else do you need to carry? The further you need to take them, the more you will appreciate wheels. I'd love to see what you wind up with.