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My Plano tackle box is running out of room and since I have the money, I figure Battle Foam is finally an option I'm willing to try, especially now that I've seen their smaller sized bags first hand as I don't want to have too large of a transport for my small army. Would anyone familiar with Battle Foam's GW-sized trays be able to give me recommendations for an army of the following size?

1 Terminator HQ with protruding weapon

4 Space Marines with outstretched pointing finger
2 Space Marines with dual pistols
2 Space Marines with dual knives
2 Space Marines with meltagun held pointing straight up
2 Space Marines with missile launchers
28 Space Marines

Total: 40 Space Marines

1 Dreadnought

3 Drop Pods
5 Rhino chassis
3 Predator weapon options
3 Whirlwind weapon options

What would be the smallest Battle Foam case I could get that will store all these models? I don't want to carry a transport that is larger than a normal suit case like the giant Citadel cases or the rolling style transports. Sorry if this is the wrong section. I normally try to find out the measurements myself but Battle Foam has so many modules and case options, and it's hard to get a clear picture of exactly how big the item will be in real life.

Have you tried contacting their customer service?

They'd probably have a much better idea of what to suggest.

As I understand it, their CS folks will actually work with you over the phone or email (assuming they're not too swamped, like during Black Friday) to plan stuff out like this.

I can personally attest to it, call em up!

Provided a list of models/sizes to work with they can suggest the best pre-made trays you need or make a set of custom ones for you.

Not to beat the dead horse so to speak, but their customer service is awesome. They can help you with anything.

I will attest to the quality of their bags, I own 3 (1 stock Warmachine, 1 Hordes with Custom Foam loadout (using stock trays), and 1 stock Malifaux), their bags are awesome and I've never had issues with them, even so much so that my Malifaux bag has traveled with me through Customs, 2 airports and port authority with no trouble.

My issue with them was their customer service in the communication department. I'm fairly certain that the above advice of call them and they will help you out is sound, but when I ordered my Malifaux and Hordes bags, I ended up waiting 10 weeks for my product when their custom order says it will take 6 to 8 weeks. This was in February of last year, nothing about my order was strange (the Hordes bag was filled with their medium troop trays, the Trollbloods Warbeast Tray and the Khador Warjack Tray, all "stock" on their site), and I emailed them after the 4 week mark, thinking everything was a regular order, since I didn't create custom foam, I was told that it was considered a custom job and would take 6 to 8 weeks to complete. That was the last I heard until my bags arrived 2 weeks after they said they would.

Like I said, I love the 3 cases I have, they've held up for a year (warmachine bag is about a year and a half old), and were being used almost twice a week for 10 months (Malifaux is the only one that is a solid once a week use now). Just beware if you order around this time, it might take longer than the 8 weeks they say on their site especially if they're prepping for AdeptiCon.

Don't buy their premade foam unless it EXACTLY fits your needs. Take the time to measure your models and put together your own trays. I have a number of trays I created on my own that, although they fit less models than the BF tray, allow me to use LESS BF trays, because the ones I build have spots for all my models, where the BF trays didn't have enough larger spots.
It'll take hours, most likely, but you'll be better off in the end.

You could have them do it but, with the time it will take to make all the paper templates & fax them in, you could just have done your own tray.

Eric