Hello Mr. Jones...
To answer your question.. I have done trays for different types of humidor's.. cabinet's, wine coolers and coolerdor's
Spanish Cedar is very pricy when you can locate it.. My local bends me over the counter with no lube.. when they see me coming (I recently posted a rant thread on this) So I purchase alot from other sources (shipping costs)going rate is usually around $6-7.50 a bdft=(board foot= 12"L X 12"W X 1"T or 144 sq inches) rough sawn or sanded 2 sides... once that arrives I then have to rip it to thickness IE: 3/8", 1/4", 1/8", plane it to smoothness 4 sides just to have it ready to be worked into a project... this all takes electricity, wear on equipment and man hours to get completed... then comes completed trays and shipping costs count in the packing materials so no damage occurs.. and anything in a shipping box/container 24" or longer the postage has a surcharge added...
Now granted if I had mass orders for coolerdor' trays it would be worthwhile to both myself and customers because I could then round the total costs in and keep overhead lower...
Please don't take this post as me being an **** about this, but that is what I have to look at when doing a project...
Now how much would you be willing to pay for these trays for your coolerdor? and are you going to keep your cigars in a coolerdor through-out your cigar smoking life? or one day pull the trigger on a nice size Cabinet Humidor where added custom trays would get the view and Aw of friends and neighbors?
You may want to look into local shops and grab some empty cigar boxes to slide those five packs into your coolerdor'.. this would be more cost effective...
Hog