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Bought two of the cheap 16" Pelican knockoffs from Sam's Club as well as the Plano "All Weather Tactical" rifle case for my AR. Cases themselves are good enough for my needs (no plans to ship them on airplanes or anything), but both types came with pluck foam. Not only that, but the small Sam's cases had a lower non-pluck foam piece that was just as thick as the pluck part, making it fairly unusable. Kaizen foam to the rescue.
I ordered 2 sheets of the 2 1/4 Black/white foam, a marker, and a knife (and a thin blade pack that I never opened as I never found I needed them).
First, I replaced the foam in my rifle case. Original plan was to cut all the way through like the pluck foam but decided I wanted the white to show when the slot was empty (tool control
) so I carefully peeled the layers as low as I could. Looks kind of sloppy if you look real close but I was happy with the results.
Empty:
Filled:
(Indents in the foam are from the strap I removed for the pictures). I placed the weapon off center intentionally to leave room for more accessories or a future handgun. In retrospect I should have cut the mag slots above the stock for better utilization of space...
The foam is slightly thicker than the pluck foam I moved (1/8" maybe?) so it sticks up just a tiny bit; also, because I chose to not cut all the way through (I may yet) the weapon rides higher in the new foam than the old where it could sink into the lower foam (still there). Makes it a bit tighter in the case but not too much so.
Next, the Sam's Club "pistol" cases. These came out cool!
I ordered 2 sheets of the 2 1/4 Black/white foam, a marker, and a knife (and a thin blade pack that I never opened as I never found I needed them).
First, I replaced the foam in my rifle case. Original plan was to cut all the way through like the pluck foam but decided I wanted the white to show when the slot was empty (tool control
Empty:

Filled:

(Indents in the foam are from the strap I removed for the pictures). I placed the weapon off center intentionally to leave room for more accessories or a future handgun. In retrospect I should have cut the mag slots above the stock for better utilization of space...
The foam is slightly thicker than the pluck foam I moved (1/8" maybe?) so it sticks up just a tiny bit; also, because I chose to not cut all the way through (I may yet) the weapon rides higher in the new foam than the old where it could sink into the lower foam (still there). Makes it a bit tighter in the case but not too much so.
Next, the Sam's Club "pistol" cases. These came out cool!