So I decided to try my hand at making a custom rifle case. I had a Plano All-Weather case and I picked up a 2'x4' sheet of 2-1/2" of kaizen foam from Home Depot for $30. The kaizen foam is layered. You can cut to a depth and peel the layers off to created the cavity. Or that's what's supposed to happen.
The end product doesn't look too bad. I didn't do a good job of space management. I cut the rifle space before trying to see where everything else would go. Ideally, I should have used a 42" case to make sure I had room for everything and room to add some more stuff as needed.
One issue I had was the layers did not peel cleanly. I tried to flatten the cavity as best I could but it is far from perfectly even. I used a box cutter to cut the cavities. A few times I took the blade out of the cutter to shave the bottom on the cavity to make it as even as possible. It works for my purposes but it's sure not something I'd try to sell. The silver is from the sharpie I used to mark the outlines of the items.
The hole in the foam is cut for clearance for the remote switch for the light. I have a bit of foam left over. I may try to find a pistol case to use it in.
The end product doesn't look too bad. I didn't do a good job of space management. I cut the rifle space before trying to see where everything else would go. Ideally, I should have used a 42" case to make sure I had room for everything and room to add some more stuff as needed.
One issue I had was the layers did not peel cleanly. I tried to flatten the cavity as best I could but it is far from perfectly even. I used a box cutter to cut the cavities. A few times I took the blade out of the cutter to shave the bottom on the cavity to make it as even as possible. It works for my purposes but it's sure not something I'd try to sell. The silver is from the sharpie I used to mark the outlines of the items.
The hole in the foam is cut for clearance for the remote switch for the light. I have a bit of foam left over. I may try to find a pistol case to use it in.