Ben,Up to 1,000 in a 3800 case, but extremely tight! You have to cut boarder foam to make it work unless you can find the awesome Racks that @joeyshin has which are 4 rows of 25 chips with lids as opposed to our standard 5 rows of 20 chip racks. Also love that this system stores the chips In a vertical arrangement (many discussions in the past about chip warpage being caused by chips laying horizontally...any truth in it? Definitely possible)
A standard 800 layout in a 3800 would be 2 high with 3 racks left to right and one row top to bottom as shown here
View attachment 981498
No idea where all these supposed "800 chips are tight in a 3800 case" came from but that is an absolutely FALSE statement.
To fit 1,000 chips cut the left and right side foam down to 50% thickness and add another row of chips to the right. Then it is tight. As shown
View attachment 981499
This is only 900 chips so you can see the edge of the yellow $20s is not sitting perfectly flat. It is only resting on soft roam below. For odd # racks your can add a number of products like thin wood, lexan, fiberglass sheeting to lay on top of the soft foam and keep the rack positioned properly. Unfortunately for this set I have 2 - 20 chip tunes holding my spares and hundos under that final rack on the right, so I have not added a stable floor for that rack, it requires a lot of qdditonal cutting with the tube below and just haven't gotten around to it.
If you are planning on going 4800 for 800 chips I hope you are also planning to pack, over night clothes. 4 pistols, 2 tacobell party 12 packs and a case of beer... because your chips are going to look lost in that huge case!
A question for you. With the chips open in racks (Chipco)), are the racks simply stacking on top of the other chips? Or are you putting a layer of foam between the rack bottoms and the chips below?
Thanks,
Mud