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 Custom Cut Foam for Gun Cases

How to Custom Cut Foam for Gun Cases

Custom cutting foam for a Pelican gun case is a process that ensures your firearms are snugly nestled and protected during transport or storage. Whether you are a hobbyist, hunter, or professional, properly fitted foam not only secures your firearms but also prevents damage caused by movement and impact. Follow these steps to tailor foam inserts for your Pelican gun case:

Assess Your Needs

Begin by evaluating the layout of your firearms and accessories. Determine the dimensions of your Pelican gun case and the items you intend to store inside. Understanding the arrangement will guide you in planning the foam cutouts.

Select the Right Foam

Opt for foam inserts specifically designed for customizing Pelican gun cases. These Pelican gun case foams are often available in different thicknesses and densities. Choose a foam density that provides adequate cushioning without being too soft or too firm.

Gather Tools

You will need precise tools for cutting foam. A sharp utility knife or an electric carving knife works well for this task. Additionally, consider using a marker for outlining and measuring tools for accuracy.

Create a Template

Before cutting the foam, it is advisable to create a template of your items on a piece of cardboard or paper. This allows you to plan the layout and ensures that your cutouts are accurately positioned.

Mark the Foam

Place the foam sheet inside your Pelican gun case. Using your template as a guide, mark the outline of your firearms and accessories onto the foam with a marker. Take your time with this step to ensure precision.

Cut the Foam

With the outlines marked, carefully cut out the shapes using your utility knife or electric carving knife. Start by making shallow cuts and gradually deepen them until you reach the desired depth. Take caution not to cut too deep, as this can compromise the structural integrity of the foam.

Test Fit

After cutting out the shapes, test the fit of your firearms and accessories in the foam inserts. They should fit snugly without being too tight. Make any necessary adjustments by trimming or reshaping the foam as needed.


Pay attention to details such as trigger guards, scopes, and other protruding parts. Use a finer cutting tool or sandpaper to refine the edges and ensure a precise fit. The goal is to create a seamless custom foam insert that securely holds your items in place.


Once you are satisfied with the fit, clean any debris or excess foam from the inserts. Ensure that all cutouts are smooth and free of rough edges. Your custom foam inserts are now ready to protect your firearms in your Pelican gun case.

Remember, patience and precision are key when custom cutting foam for your Pelican gun case. Take your time during each step of the process to ensure a professional-looking result.

Choose Premium Foam Inserts for Gun Cases

With our properly fitted foam inserts, you can safely transport your firearms knowing they are secure and protected from damage. Contact us today to learn more about our custom cut foam inserts.

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