Slice and Pluck



Cus­tom-cut­ting hard case foam to fit your gear like a glove

Yes, they are im­pres­sive to look at, aren’t they? They of­ten con­jure up thoughts of se­cret agents and scenes from your fa­vorite ac­tion movie. We’re talk­ing about wellap­pointed hard cases com­plete with a se­lec­tion of equip­ment en­cased in a bath of poly­eth­yl­ene foam.

Most ev­ery gun en­thu­si­ast has seen a decked­out hard case with a per­fectly cut foam in­sert filled to the brim with cool weaponry and accessories. Some say this type of setup isn’t nec­es­sary or practical while oth­ers say that it of­fers great pro­tec­tive prop­er­ties. Re­gard­less, we can prob­a­bly all agree that a fully set up hard case does look stun­ning. We de­cided to tackle the chal­lenge to see how it’s done and how dif­fi­cult (or easy) it is to do.

We’ll pref­ace this DIY by say­ing that we have never at­tempted this type of project be­fore, so the re­sults you see here are real, unedited and (spoiler alert) not perfect by any stretch of the imag­i­na­tion. What we did find out while tak­ing on this job is that it isn’t dif­fi­cult, but it does de­mand pa­tience and at­ten­tion to de­tail. That said, our first job was to fig­ure out what tool we wanted to use to cut the foam. After test­ing mul­ti­ple tools, we de­cided for our pur­poses that an elec­tric carv­ing knife, like one that you’d carve a turkey with, was the right tool for the job. For more about our cut­ting tools trial, take a look at the side­bar, The Right Tool.

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