Just wanted to share my experience and materials I've found if anyone is looking to upgrade their rifle case(s) withoutbbreaking the bank. I've posted about it on a couple other forums, so if you happen to be seeing this again after seeing it on another site, my bad!
Several years ago, I decided I wanted to make an interior for my Plano All Weather XL pistol case. It held handguns, but with all the vertical space it just seemed like a waste. I got some inspiration from CaseClub's custom interiors, and through another site discovered kaizen foam. Kaizen is a closed cell foam made up of several 1/8" layers glued together, making it able to be cut and peeled to different depths. Here's what I ended up with for my pistol case. I have since added 2 more slots (seen in the 2nd picture) and added relief to one for another revolver (not shown), but it gives the basic design. I stacked 2 layers of the foam and glued them together to be able to do this design.
This year, I decided I wanted to do some nicer inserts for my rifle cases as well. The cases I used are two Planos (a 52" All Weather and a 42" All Weather Tactical) and a "Members Mark" case formerly sold at Sam's Club. The 52" case for my Savage 10 I used a CaseClub foam sheet because the Kaizen foam only comes in sheets up to 48" at least that I've found affordably whereas the CaseClub foam is 53". I cut it to shape, then traced the outline and used break off utility knives to cut out the shape. Unlike Kaizen, you can't seperate layers so I had to cut all the way through.
This week I ordered 2 sheets of Kaizen for my last two cases for my Weatherby Vanguard and AR. This time, I used an electric carving knife to cut them to size, and after tracing I used a drywall cutout tool from Harbor Freight to cut the outline (https://www.harborfreight.com/electric-cutout-tool-42831.html). After cutting the outline, the layers can be peeled to that depth (the cutout tool at its deepest goes about 3/4 of the way through, which is about what I was aiming for. With some more patience they could have turned out neater, but I like them fine and they're definitely plenty functional.
Several years ago, I decided I wanted to make an interior for my Plano All Weather XL pistol case. It held handguns, but with all the vertical space it just seemed like a waste. I got some inspiration from CaseClub's custom interiors, and through another site discovered kaizen foam. Kaizen is a closed cell foam made up of several 1/8" layers glued together, making it able to be cut and peeled to different depths. Here's what I ended up with for my pistol case. I have since added 2 more slots (seen in the 2nd picture) and added relief to one for another revolver (not shown), but it gives the basic design. I stacked 2 layers of the foam and glued them together to be able to do this design.
This year, I decided I wanted to do some nicer inserts for my rifle cases as well. The cases I used are two Planos (a 52" All Weather and a 42" All Weather Tactical) and a "Members Mark" case formerly sold at Sam's Club. The 52" case for my Savage 10 I used a CaseClub foam sheet because the Kaizen foam only comes in sheets up to 48" at least that I've found affordably whereas the CaseClub foam is 53". I cut it to shape, then traced the outline and used break off utility knives to cut out the shape. Unlike Kaizen, you can't seperate layers so I had to cut all the way through.
This week I ordered 2 sheets of Kaizen for my last two cases for my Weatherby Vanguard and AR. This time, I used an electric carving knife to cut them to size, and after tracing I used a drywall cutout tool from Harbor Freight to cut the outline (https://www.harborfreight.com/electric-cutout-tool-42831.html). After cutting the outline, the layers can be peeled to that depth (the cutout tool at its deepest goes about 3/4 of the way through, which is about what I was aiming for. With some more patience they could have turned out neater, but I like them fine and they're definitely plenty functional.
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