Here are a couple of suggestions people have made.
Stored in the sheets (The third post on this thread.)
What I did was make inserts to divide it all within the box. seems to work out for me although I haven't tried with the NPC Codex Box yet.
Since I have both pawns and minis, I store the pawns in the same case as the minis (I use Stanley Totes, personally). However, I don't use pawns all that often, so most of mine are still in their shipping material.
On the other hand, I've found the pawns to be awesome in combat for use when a creature is down but not necessarily dead, since they're flat and other minis can just stand on them. I don't remove dead creatures from the battlefield - after all, a smart opponent will heal their allies if they can, and it makes the PCs just a wee bit more nervous.
This is also important for creatures like, say, trolls :)
Here's what to do. Go buy a big (2-3") 3-ring binder. Then, find where magic the gathering, pokemon, and baseball cards are sold in the store you're in (target has them). In that area, look for ultra-pro sheets with 9 cells for storing collectible cards. Punch out the pawns and organize them by size and then by number in the plastic sheets, and store them in the 3 ring binder. Each plastic compartment will hold 2 small or medium creatures or one large creature. There will be a few huge creatures in each box; collect all of them and keep them in one of the empty pawn boxes.
That's what I do, and it works like a charm. All told, this should cost about 20 bucks.
Some good ideas here. Doc's will work with the AP pawn sets, too, which don't have a box.
Gonna have to go look at Stanley Totes.
I worried for quite some time about the perfect storing system... And then I figured I would just leave them in their cardboard sheets. I just press them out when I need them, and push them back in when done.
That can work for quite a while, although I've found eventually they're worn through enough that this becomes a hassle.
Cut cereal boxes into 1 inch stips.
Take one of the punch sheets that has space for a mix of sizes.
Using masking tape tape the strips perpendicularly to the punch sheets so that they form walls around each cut out space.
Cut notches in the strips at intersections and tape for strength. Basically this should look like a cardboard tackle box. Drop the whole thing in a box that it fits somewhat snugly. Or glue it to the bottom of a box that is not so snug.
Insert pawns into the correct sized cubby.