Dave said,
I'd like to fill the box with some sort of foam (with a fabric
sheet on top)that would conform to the buckle then cure to a somewhat
pliable form… kind of making a molded recepticle.<<
Would the kind of insulating foam that comes in a spray can
work? It used to be available at hardware & home supply stores.
-
Place the buckle face down on a solid surface.
-
Cover it with the fabric (might have to put a piece of saran
wrap over the fabric). -
Place a open ended container, the same size as the
presentation box, around the covered buckle. (Probably be a good
idea to let the saran wrap cover the inside of the container;
it’d make removing the solidified foam a lot easier.) Be sure to
locate the buckle where it’ll be in the finished box. -
Spray in the required amount of insulation foam.
-
Trim off the excess foam.
-
Put the fabric over the foam & place the buckle bed in the
presentation box.
I’ve seen this approach, with a similar type of foam, used to
pack & ship video monitors.
Good luck!
Dave