Converting my Versa 500 chip case into a 600 chip case

alecnetwoodworks

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Thanks again @RainmanTrail for your interest in some custom inserts and starting this post. Been crazy busy today and finally found some time to sit down and look over this in more detail. Figured I'd just go direct to the source here.

So based on the provided measurements that Rainman provided me for these Versa cases, we're looking at an insert with 12 columns of ~50 chip rows (from my math the 7in deep insert should actually hold about 52 chips, maybe even 53 paulsons?) with dimensions of 20.875in wide (530mm) x 7in deep (177mm) and no stops front or back.

Given those guidelines I can offer the following prices (as long as I get at least 5-10 inserts to make at the same time. Don't have be to be same material)

MDF - $30 ea
Furniture grade Pine or Wormy Maple (my usual choice for chip trays/inserts and least expensive locally available hardwood)- $45 ea
Standard domestic hardwoods (red/white oak, cherry, ash) - $50 ea
Premium hardwoods (walnut, mahogany, exotics, etc) - $55 and up depending on actual wood cost

These all assume a standard clear finish. Stained or painted (MDF) would be a little extra. Shipping will be actual cost.

At the moment, lead time is fairly long at around 8 weeks since I'm super busy with a big local project (and a whole bunch of poker chip boxes I need to get out in Feb), but with enough interest in these, I may make some extras to keep on hand for the future in whatever options are most popular.

There was some talk earlier in this thread about router bit sizes. For 39mm chips my standard is a 1.625in core box bit (which is still pretty tough to find). Rainman's math is correct on the actual metric size there and I've yet to find a vendor for anything closer in size (like the 40mm bit mentioned), but I've found that size bit to work quite well for 39mm chips and had no complaints from clients. For 43mm chips I use a 1.75in core box bit. I use a router table and template spacers to make this type of insert. A CNC machine would be even better, but I don't have space for one in the shop at the moment (unless my wife lets me take over the basement, but approximately zero chance in that happening anytime soon...)
 

mtl mile end

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Thanks again @RainmanTrail for your interest in some custom inserts and starting this post. Been crazy busy today and finally found some time to sit down and look over this in more detail. Figured I'd just go direct to the source here.

So based on the provided measurements that Rainman provided me for these Versa cases, we're looking at an insert with 12 columns of ~50 chip rows (from my math the 7in deep insert should actually hold about 52 chips, maybe even 53 paulsons?) with dimensions of 20.875in wide (530mm) x 7in deep (177mm) and no stops front or back.

Given those guidelines I can offer the following prices (as long as I get at least 5-10 inserts to make at the same time. Don't have be to be same material)

MDF - $30 ea
Furniture grade Pine or Wormy Maple (my usual choice for chip trays/inserts and least expensive locally available hardwood)- $45 ea
Standard domestic hardwoods (red/white oak, cherry, ash) - $50 ea
Premium hardwoods (walnut, mahogany, exotics, etc) - $55 and up depending on actual wood cost

These all assume a standard clear finish. Stained or painted (MDF) would be a little extra. Shipping will be actual cost.

At the moment, lead time is fairly long at around 8 weeks since I'm super busy with a big local project (and a whole bunch of poker chip boxes I need to get out in Feb), but with enough interest in these, I may make some extras to keep on hand for the future in whatever options are most popular.

There was some talk earlier in this thread about router bit sizes. For 39mm chips my standard is a 1.625in core box bit (which is still pretty tough to find). Rainman's math is correct on the actual metric size there and I've yet to find a vendor for anything closer in size (like the 40mm bit mentioned), but I've found that size bit to work quite well for 39mm chips and had no complaints from clients. For 43mm chips I use a 1.75in core box bit. I use a router table and template spacers to make this type of insert. A CNC machine would be even better, but I don't have space for one in the shop at the moment (unless my wife lets me take over the basement, but approximately zero chance in that happening anytime soon...)
*I don't own any of these cases and am not a potential customer*

Wouldn't a softwood be the choice here? Poplar maybe? Am I missing something?
 

alecnetwoodworks

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*I don't own any of these cases and am not a potential customer*

Wouldn't a softwood be the choice here? Poplar maybe? Am I missing something?
Poplar is a hardwood, though it's a fairly soft one, and would be an acceptable option as well. I'd put it there with pine and wormy maple. It is light and machines well, but not terribly attractive.

Appearance is going to be the biggest difference between the options, honestly. If you dont care about that, mdf is the ideal choice for the application. Stable, flat, and cheap.
 

BEANO52

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I did some measuring on mine and if you were to remove the 2 pieces from each "inside tray" labeled 1 and replace the middle section with a piece cut down (or made) the width indicated by 2 you could perfectly fit 3 rows in the middle.

chip case2.jpg


It would basically be a continuation of the pattern going with 3 extra rows.
 

Eloe2000

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I did some measuring on mine and if you were to remove the 2 pieces from each "inside tray" labeled 1 and replace the middle section with a piece cut down (or made) the width indicated by 2 you could perfectly fit 3 rows in the middle.

View attachment 624557

It would basically be a continuation of the pattern going with 3 extra rows.

I think @RainmanTrail tried it and said you could only fit 2 rows. I would love to maximize the space. I know 650 chips sounds odd to some people, but that is a pretty sweet number for my optimized cash sets.
 

BEANO52

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I think @RainmanTrail tried it and said you could only fit 2 rows. I would love to maximize the space. I know 650 chips sounds odd to some people, but that is a pretty sweet number for my optimized cash sets.

I didn't see that but on mine I measured and it would basically exactly fit 3 rows down the middle. You need to remove the 2 pieces (labeled 1 in my photo) and it is a perfect fit 500 to 650.
 

BEANO52

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Here's a pic, I shot straight down over the tapes for an accurate showing of the measurement. Honestly, an 1/8" to spare, would be perfect :)

3 racks = 4 1/2" wide. Available space = 4 5/8".

20210128_210343-COLLAGE.jpg
 

RainmanTrail

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I think @RainmanTrail tried it and said you could only fit 2 rows. I would love to maximize the space. I know 650 chips sounds odd to some people, but that is a pretty sweet number for my optimized cash sets.

It's possible to fit 13 rows in these, but I don't think they'd quite fit in the center without first removing the outside pieces/bumpers as well. One of the main problems I have with these cases is that the rows are actually too narrow. If you put 39mm chips in the rows, they don't sit on the bottom, they rest on the rails of the rows instead. The diameter of the milled rows is 1.5", which is less that the diameter of pretty much every chip set any of us would put in there. It also causes the chips in adjacent rows to touch. They butt right up to the rows on either side. To each their own, but I don't want my chips resting on the rails and touching other rows of chips. Especially if I'm transporting them. They'll get damaged eventually. I want a little bit of space between each row, like what you'd get from Pauslon racks. I'm going to be replacing the inserts in mine with a wood insert that has 40mm diameter rows and about 1mm of space between each row. Personally, this is the best solution for my preferences. I think you could maybe squeeze 13 rows in there, but it'd be suuuper tight if so.
 

RainmanTrail

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3 racks = 4 1/2" wide. Available space = 4 5/8".

You should measure the chips, not the spacing. Especially if you're measuring the space between round objects from above. The diameter of 3 Paulson "39mm chips" (more like ~39.3mm) is wider than 4 1/2". It's also wider than 4 5/8". They won't fit in the center without running into the other chips. To get 3 more rows in, you'd have to redo the entire space and remove the outer rails on each side.

1611892596839.png
 

BEANO52

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Maybe this will explain what I am talking about easier. It is 100% perfect fit with mine. 100% perfect.
I don't have yours in hand so cant speak to that but it looks exactly like mine.

chip tray2.jpg


Each chip is 1.55" +/-
13 chips across is 20.15" +/-
Measure from outside chip to outside chip in case = 20.25"
perfect fit
 
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RainmanTrail

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Maybe this will explain what I am talking about easier. It is 100% perfect fit with mine. 100% perfect.
I don't have yours in hand so cant speak to that but it looks exactly like mine.

View attachment 624684

Each chip is 1.55" +/-
13 chips across is 20.15" +/-
Measure from outside chip to outside chip in case = 20.25"
perfect fit
Yes, I understand that. I agree that 13 rows *can* "fit" inside the case. What I'm saying is that the chips touch each other though. Just look at your chips that are currently in the case. I guarantee they're touching each other already, and not sitting down fully into the grooves if you have a Versa case. Perhaps you don't care about this, but I do. I want space between the rows of my chips.
 

raynmanas

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I recently bought a couple of the Versa 500 chip cases that are so popular here. I've seen enough people rave about them that I finally decided to take the plunge. I have a couple of the Pelican style cases with custom foam inserts as well, but those things are super bulky and I wanted something a little more convenient for traveling with sets. I also am not a fan of the 600 chip carrying cases that have racks stacked inside them as the bottom racks are very difficult to remove and they just seem awkward to me.

I bought these with the intention of converting them into 600 chip cases since 500 chips just isn't big enough for most cash games IMO. 600 chips is still less than optimal, but it's at least doable. I've reached out for some help from @alecnetwoodworks to see if he might be able to make me a nice custom hardwood insert for these to make them a little nicer than the solution I came up with below, but I figured I'd share my temporary solution below to show what I did here in case anyone else wants to do the same.

Basically, I just removed the center insert that is designed to hold cards, and replaced it with 2 more rows. I removed one of the row inserts from my 2nd case and trimmed it down to size using a razor blade (it cuts easily since it's made from some sort of particle board). Obviously, this requires you to "ruin" one of your Versa cases, but you could use something else for the rows if you wanted to (3D printed insert from @One Eyed Dollar perhaps)?

Eventually, I hope to have a nice hardwood insert in these that will hold 600 chips in evenly spaced rows. But for now, this is my new and improved Versa 600 chip case.


View attachment 613970
View attachment 613972View attachment 613976View attachment 613974View attachment 613975View attachment 613971

This is so much fancier than the "mod" I did, which includes a piece of the packing foam from the case:

20200713_172022.jpg
 

Eloe2000

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I just got my cases in and pried out the pieces. There is definitely no way to do three rows without reconfiguring the whole thing and cutting corners etc. Three rows just simply don’t fit into the center space as is.

Edit: it works if you take out the end pieces as well. It’s tight, but appears that it will work.
 
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BEANO52

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If anyone redoing these ends up with spare piece 3 rows wide i will purchase it. Let me know :)

Edit: I will actually be looking for 2+ or more 3 row sections as I have a second case coming. Thanks for the consideration !
 

Eloe2000

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If anyone redoing these ends up with spare piece 3 rows wide i will purchase it. Let me know :)

Edit: I will actually be looking for 2+ or more 3 row sections as I have a second case coming. Thanks for the consideration !
I see that if you took out the end border pieces and clipped the corners of the racks you might be able to squeeze out enough space while still leaving enough room for three rows without the chips touching each other or the sides of the case but boy is that tight.
 

Eloe2000

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Update: if you take out the end pieces as well (no need to clip corners) the chips do not touch the side of the case and three rows will fit.
0E19DDFE-150C-4F93-B353-2869E81FC85D.jpeg
3C95D62F-B2FE-47F8-9F58-2D9FB66DFE05.jpeg
 

RainmanTrail

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If anyone redoing these ends up with spare piece 3 rows wide i will purchase it. Let me know :)

Edit: I will actually be looking for 2+ or more 3 row sections as I have a second case coming. Thanks for the consideration !
I have some spare sections. PM me your address and I'll send them to you.
 

liftapint

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I exclusively use Versa cases and someone did that tutorial on stripping and converting a Versa 1000 into a 1100 or 1200 chip case with Pauslon racks (I forget who).
I can't find this either. Does someone with better searching skills than mine, have a link to this?
 
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