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
I've seen this approach, with a similar type of foam, used to
pack & ship video monitors.