Here's a shot of the foam core grid that the cut swabs will go into. This took A LOT more time than I thought it would to create. First part was to cover the foam core with some grid paper I bought and then poke a hole at each intersecting line with a push-pin. After the initial holes were created I could remove the grid paper and cut down the foam core board to the correct size.
The problem I had now was that the holes weren't any where near the size they needed to be to accommodate the cotton swabs. I had to go over the entire surface again with a small screwdriver to enlarge each hole... all 1,665 of them.