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    • Best Ducks for Eating
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    • Camping on the beach tips
    • Can you Shoot Guns While Pregnant
    • Carbine vs Rifle
    • Carbon Arrows Vs Aluminum
    • Caribou vs Moose
    • Compound Bow vs. Crossbow
    • Concealed Carry Guide
    • Drop Point vs Clip Point
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      • Alaska Fishing
      • Baitcaster vs Spinning Reel
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        • Bass Fishing California
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      • Best Catfish to Eat
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      • Best Fishing Songs
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      • Cane Pole Fishing
      • Casting Reels vs Spinning Reels
      • Crappie
        • Crappie Fishing Alabama
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        • How to Catch Crappie
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        • Kayak Crappie Fishing Tips
      • Do Fish Bite in the Rain
      • Flounder vs Halibut
      • How does a Fish Finder Work
        • Down Imaging vs Side Imaging Sonar
      • How to Guides
        • Catch Bass on Frog Baits
        • Catch a Big Brown Trout
        • Catch Garfish
        • Catch a Rainbow Trout
        • Catch Walleye
        • Change A Fishing Reel From Right To Left Handed 
        • Clean a Spinning Reel
        • Clean Trout
        • Get Fish Oil Smell Out Of Clothes
        • Pickle Northern Pike
        • Spool a Spinning Reel
        • String a Fishing Pole
      • Jerkbait and Crankbait
      • Lake Nockamixon Fishing
      • Monofilament Line vs Fluorocarbon
      • Pickerel vs Pike
      • Sabiki Rigs
      • Sailfish vs Marlin
      • Species of Fish in Lake Tahoe
      • Spotted Bass vs Largemouth
      • Standley Lake Fishing
      • Strongest Fish
      • Trout Species
      • Types of Fishing Line
      • Types of Sinkers
      • Walleye Trolling Speed
      • What do Carp Eat
      • What Is Fly Fishing
    • Guide to AR15s
    • Guide to Jet Skis
    • Gun Maintenance Guide
    • How Does a Boat Speedometer Work
    • How to Guides
      • Aim a Glock
      • Blue a Gun
      • Build An Emergency Winter Shelter
      • Butcher A Rabbit
      • Charge a Trolling Motor Battery
      • Choose The Right Rangefinder
      • Clean a Life Jacket
      • Clean Swim Goggles
      • Conceal Carry with a Tucked-In Shirt
      • Cook Wild Goose
      • Cure And Smoke A Venison Roast
      • Cut an Arrow
      • Cut Foam For Gun Case
      • Dispose of Bullets
      • Dispose of Knives 
      • Find Arrowheads
      • Fit Hiking Boots
      • Get A Hunting License In California
      • Get off a Ski Lift
      • Heat A Tent Without Electricity
      • Hide a Gun Safe in Plain Sight
      • Insulate a Tent for Winter Camping
      • Keep Moisture Out of a Gun Safe
      • Keep RV Pipes From Freezing
      • Long Does It Take To Swim A Mile
      • Make Deer Jerky
      • Make A Leather Gun Holster
      • Mount Your Own Deer Antlers
      • Move a Gun Safe
      • Open a Gun Safe Without a Key
      • Pack a Backpack for Hiking
      • Pack a Tent In a Backpack
      • Parts of a Pistol
      • Prepare And Cook Venison Tongue
      • Remove Gun Rust
      • Sharpen a Knife Without a Sharpener
      • Sharpen a Machete
      • Sharpen a Pocket Knife
      • Ship A Firearm
      • Shoot a Compound Bow
      • Sight In a Compound Bow
      • Sight in a Red Dot
      • String a Compound Bow
      • Swim Faster
      • Tan a Deer Hide
      • Tan a Rabbit Hide
      • Teach Kids to Ski
      • Teach a Toddler to Swim
      • Transport Paddle Boards
      • Transport a Firearm by Boat
      • Use a Laser Bore Sight
      • Use a Slingshot
      • Use A Tactical Pen
      • Wash Hiking Boots
      • Wash Hunting Clothes
      • Waterproof a Wound for Swimming
      • Wax a Boat
      • Wear a Boot Knife
      • Winterize a Jet Ski
    • Hatchet vs Tomahawk
    • How Far can a Bullet Travel
    • How Far Can Crossbows Shoot
    • Hunting Tips
      • Best Apps
      • Best Hunting Dog Breeds
      • Black Bear
        • How Fast are Bears
        • What does Bear Poop Look Like
      • Bow Hunting For Beginners
        • Can Felons Bow Hunt
        • Types of Hunting Bows
      • Can you Eat Raccoon
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        • Coyote Hunting Kentucky
        • How to Skin a Coyote
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        • Best Barometric Pressure for Deer Hunting
        • Best States for Mule Deer Hunting
        • Blacktail Deer vs Whitetail Deer
        • Deer Gestation Period
        • Draw Weight to Kill a Deer
        • How to Age a Whitetail Buck
        • How to Clean a Deer Skull
        • How to Grunt for Deer
        • How Long Does Deer Meat Last in the Freezer
        • How Long to Hang Deer
        • How Much Meat From a Deer
        • How Much Wind is Too Much for Deer Hunting
        • How Rare is a Piebald Deer
        • Hunting deer in California
        • Mule Deer vs Whitetail
        • Poop
        • When Do Deer Shed Their Antlers
        • Where to Shoot a Deer
        • Whitetail Deer Guide
        • Wisconsin Deer Hunting
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        • Dove Hunting Mexico
        • Dove Hunting in Texas
        • What to Wear Dove Hunting
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        • Best States for Duck Hunting
        • How to Use a Duck Call
        • Hunting Dog Breeds
        • Hunting in Florida
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        • Hunting in Michigan
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        • Hunting South Carolina
        • Hunting South Dakota
        • Hunting in Tennessee
        • Hunting in Utah
        • Hunting in Wisconsin
        • What to Wear Duck Hunting
      • Foxes
        • Trap a Fox
      • Frog Gigging
      • Geese
      • How to Keep Feet Warm While Hunting
      • Pheasant
        • What to Wear Pheasant Hunting
      • Rabbit
        • Where to Shoot a Rabbit
      • Squirrel
      • Turkey
        • Hunting in the Rain
        • Turkey Hunting Kentucky
        • Turkey Hunting Michigan
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        • Turkey Hunting Oklahoma
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        • Turkey Hunting Texas
        • Where to Shoot a Turkey
      • Where to Shoot a Hog
      • Why Do Hunters Wear Orange
    • Irish Setter Hunting Boots
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      • Hazards around Dams
      • How Long to Kayak a Mile
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      • How to Tie Down a Kayak in a Truck Bed
      • How to Use a Kayak Cart
      • Most Stable Kayak Hull Design
      • Sit on Top vs Sit In Kayaks
    • Lever Action Rifle Cartridges
    • MOA vs MRAD
    • Most Powerful Handgun
    • Parts of an Arrow
    • Pontoon Boats
      • Can a Pontoon Boat Sink
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      • How Much does a Pontoon Boat weigh
      • How to Anchor a Pontoon Boat
      • How to Winterize a Pontoon Boat
      • Tritoon vs Pontoon Boat
    • Pump vs Semi-Auto Shotgun
    • Reflex vs Red Dot
    • Reloading Ammo vs Buying Ammo
    • Rimfire vs Centerfire
    • Single Bevel Vs. Double Bevel Knives
    • Single-Stage vs Two-Stage Triggers
    • Spotting Scope vs Binoculars
    • Types of Rifle Scope Mounts
    • Ultimate Guide to Camping
    • Walkie Talkie Lingo
    • Walking vs Hiking
    • What Does Grain Mean in Ammo
    • What do the Numbers on Binoculars Mean
    • What is an Air Rifle
    • What is a Long Gun
    • What is Recoil on a Gun
    • Who Invented the Compound Bow
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Home Guides & Tips

How To Cut Foam For A Gun Case

by Justin
November 24, 2022
FOAM FOR A GUN CASE FEATURED IMAGE
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When you buy a hard gun case, it comes fitted with blank foam inserts. But unless you get the dealer to customize the foam for a specific gun, you’ll have to do it yourself. Also, you may want to use the same case for multiple firearms.

So you will need to cut foam for each configuration. This 8-step guide will show you how to cut foam for a gun case. When you cut out your own inserts, it’s easy to use the same case for hunting, range shooting, competitions, or travel.

It’s not expensive to cut your own inserts, especially when you take the value of your gun, the ammo, and the case into consideration. One option is to send specs to a place that cuts foam using a CNC machine. Another option is to order pre-cut, semi-customized inserts for specific cases and specific guns.

But you can save a fair amount by opting to get blank inserts and do the cutting yourself. With the right tools and the proper quality foam, how to cut foam for gun cases doesn’t need to be done by the dealers you buy the foam from.

Today we look at the types of foam best suited for gun cases, what you will need before you start to cut and fit your templates, and most importantly, how to cut the foam for your specific gun and case.

How to Cut Foam For a Gun Case

Different Types of Foam for Gun Cases

FOAM GUN CASEYou get many types of foam for all sorts of applications. The foams discussed here are specifically for firearms. Foam that’s too flimsy will tear easily.

It won’t offer enough support to keep the gun from getting damaged if dropped or manhandled. And most importantly, the reticle (crosshair) can get knocked out of focus if not firmly secured in the foam casing.

Gun cases come with 3 pieces of foam; convoluted foam inserts to fit into the top/lid of the case and at least two layers of foam on the bottom.

A thinner insert for the base and an upper layer insert for cutting out your configuration.

The two layers can be left separate. Once cut, you will place the cut-out on top of the bottom layer. This makes it easy to remove if you use your case for multiple weapons.

Alternatively, you may want to glue layers of foam together (or you can buy them already layered).

This is for when you won’t be cutting through the whole piece of foam, This method is more tricky, as you need to get the gun and components lined up flush with the surface and the different gun parts will be placed in hollowed out sections that will be different depths.

Most Commonly Used Foams

  • Std Polyurethane (PU) foam – open-cell foam
  • Std Polyethylene (PE) foam – closed-cell foam
  • Pre-scored Pluckable foam (pick ‘n pluck)
  • Flat/layered foam – PE or PU foam
  • Convoluted/egg crate foam, usually PU

Polyurethane Foam – Open-cell foam

This foam is not as dense as polyethylene (PE) foam. Polyurethane (PU) foam is suitable for lightweight components. It will absorb moisture. It is shock-absorbing and will protect delicate parts, like your optics.

Convoluted foam is usually made from PU foam. The convoluted foam is used in the lid of the case.

Polyethylene Foam – Closed-cell foam

case for gunThis is the most popular type of gun foam. The closed-cell foam will not absorb oils or moisture. It dampens vibrations and provides good insulation.

It is shock-absorbing and the surface can be wiped down without absorbing spills or getting stained.

Standard polyethylene foam sheets come in 35.5” x 16” sizes at thicknesses between 0.5” and 3”. These large blanks can be purchased at most foam and upholstery places.

What Will You Be Using It For?

  • Are you using the case for multiple firearms or just one?
  • Will you be traveling with this case?
  • Will you need to cut out multiple inserts for various firearms?
  • Is it a handgun case?
  • Is it a rifle case? Single or double?

You can get blank replacement inserts for specific rifle cases, like the Pelican, Nanuk, or Plano brands. Some quality gun foam brands include Appalachian Tough, Kaizen Foam, and Cobra. They will have their own range of blank inserts cut to the various sizes of cases.

Gun foam inserts come in different dimensions, with thicknesses ranging from 0.25 inches right up to 3 inches. Handgun case sizes (internal dimensions) start at (width x breadth)  12” x 12” right up to rifle case sizes of 24” x 52”. But it also depends on the brand and whether it’s a single or double gun case.

How to Cut The Foam

cut foam caseWhen you buy a case it will come fitted with a blank piece of stock foam. From here you will prepare and cut the foam for your gun case.

Assume you have a convoluted foam insert for the lid and the layer of foam at the base of the case. These instructions are solely for cutting the third piece of foam that will house the firearm, magazines, ammunition, clips, etc.

What You’ll Need

  • Blank foam insert to fit case.
  • Sharp knife for cutting big sections. (You can use an electric knife but a very sharp fillet knife or even a bread knife will do.) Alternatively, you can use a hot wire. A hot wire cut gives the smoothest finish.
  • Xacto knife, for precision cutting around intricate areas.
  • Chalk or whiteboard marker for tracing out your configuration.
  • Piece of plywood to place under foam so you don’t damage the surface you are cutting on.
  • Adhesive – if you are layering the foam. You may need adhesive if you opt for pre-plucked foam. This used to be a popular choice for DIY foam cutting for your gun case, but if you ask most gun owners, they’ll tell you to give the old pick ‘n pluck a wide berth.
  • Plasti Dip (optional). You can spray this over your finished cut-out to add strength and prevent tears. See the clip below on how to apply Plasti Dip

Method

  1. Place your foam insert on a firm surface. Place a piece of plywood (or a piece of cardboard) underneath the foam to prevent damage to the surface when cutting.
  2. Place your firearm and all the components in the position you want them to be stored in. Make sure the scope will be facing the handle and not the ground.
  3. Take your marker and trace the outline of each item. Be sure to leave at least 1” around the edge of the foam and enough space between the separate components. This increases the longevity of the foam and gives better support.
  4. Remove the firearms and components.
  5. Using your knife, or hot wire cutter, start cutting out your marked shapes. Try to cut on the inside of the chalk mark. Remember, you can always cut foam away if it’s too tight.
  6. Cut a semi-circle shape, the size of your thumb tip, somewhere on the side of each cut-out shape. This will be the space for you to place your finger to lift each item out with ease.
  7. Wipe off any remaining chalk marks and place your newly-cut foam insert into its case.
  8. Place your firearm and components into each cut-out.
  9. Admire your handiwork and snap a cold one.

See the video clip below for instructions on “How to Plasti Dip your insert”. It‘s a good idea to Plasti Dip if you are using Pull ‘n Pluck foam.

Where Do I Get Blank Foam Inserts For My Gun Case

Foam can be ordered or purchased online from:

  • Companies that manufacture and/or sell foam,
  • Amazon,
  • or from your local firearm dealerships that sell cases, accessories, and replacement foam inserts, designed to fit into the various gun cases.

Get them couriered right to your door, collect them from the post office, or buy them directly from your local gun dealers.

Time Saver: Everything You Need For The Job Here

Knives for Cutting Foam

  • Kaizen foam cutting knife
  • Kaizen knife set (5-piece)
  • Electric Hot Knife Foam Cutter (14W)
  • Electric Hot Knife Cutter 200W

Miscellaneous

  • Erasable Chalk Markers
  • Plasti Dip
  • Adhesive for foam

Blank Foam Inserts For Gun Cases

  • Pelican 1720 Replacement Foam Insert
  • Plano Case 108191 Foam Replacement Insert
  • Cobra Foam Inserts for Pelican, Plano, Apache, and Zero Halliburton

Pre-Cut Foam Inserts

  • My Case Builder: Pre-cut inserts for multiple handguns and magazines

Tutorial Video

We hope you’ve found this guide useful for making your own foam cut outs for your gun case! Don’t forget to check out the homepage for all your outdoor needs!

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Justin

Justin

Justin is a firearms enthusiast with an expansive knowledge of the firearms & hunting scene. An excellent writer, Justin is a key contributor to the OutdoorWorld Reviews website!

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