BigBL87 Posted March 5, 2020 at 06:31 PM Share Posted March 5, 2020 at 06:31 PM So, awhile back I shared my experiences making a DIY insert for my pistol case from Kaizen foam. Original thread is here: http://illinoiscarry.com/forum/index.php?showtopic=66593 Recently, I decided to make inserts for my rifle cases as well. The first one is for my Savage 10. I ended up using CaseClub foam, which similar to Kaizen but the foam layers are thicker and can't be separated, you have to cut the whole way through. I used this because Kaizen comes in 48" length but I could get the CaseClub foam in 53" length which was easier to use for the 52" case. I did this one using the same trace and snap blade knife method I used on the pistol case. I got the 52" case at the Plano outlet store for $45 (usually $150+), plug for them if you want some nice cases at crazy cheap prices. Today, I got the Kaizen I ordered in (NewEgg is still the cheapest source I've found), so went to work for my other 2 rifle cases (for my AR and Weatherby Vanguard). This time, though, since I didn't have to cut all the way through, I tried an electric cutout tool for drywall I found at Harbor Freight for $25. https://www.harborfreight.com/electric-cutout-tool-42831.html The electric cut out tool, with the provided bit, cuts just about 3/4 of the way through the kaizen sheet when fully extended, if you wanted to you could adjust the depth shallower to fit your needs. I should have worn a mask (lots of foam dust, still coughing that crap out) but it definitely gave me a straighter neater cut than the snap off blades which work fine in their own right. Here's what I ended up with. The cuts probably could have been even neater, but I'm impatient. All in all, for a $65 investment in the foam and $25 investment in a tool I'll likely reuse, I like it alot better than the pick and pluck. Link to comment Share on other sites More sharing options...
mikew Posted March 6, 2020 at 12:26 AM Share Posted March 6, 2020 at 12:26 AM Nice work, Nice rifles. I use a knife-edge blade for my cordless sabre saw, and use cardboard taped to the anvil to control the depth. Link to comment Share on other sites More sharing options...
chislinger Posted March 6, 2020 at 02:02 AM Share Posted March 6, 2020 at 02:02 AM I used mycasebuilder.com to make my foam. They will custom cut foam for any case you have, there's an app on their site for you to design your own foam and they cut it to your specs. You can pay a little extra for a free "do-over" if you're not happy with your first attempt. I was very happy with mine and didn't need the do-over. This was a cheap Cabela's case I had for a while that just had egg crate foam in it, so I decided to upgrade. Nicely holds the rifle and 6 magazines, it's a nice snug fit the finger holes make it easy to remove the rifle. https://mycasebuilder.com/ I'm very happy with that company, used them to make a microphone case too. Oh they also have templates for many popular pistols and some rifles. Link to comment Share on other sites More sharing options...
chislinger Posted March 6, 2020 at 02:05 AM Share Posted March 6, 2020 at 02:05 AM dupe Link to comment Share on other sites More sharing options...
BigBL87 Posted March 6, 2020 at 02:09 AM Author Share Posted March 6, 2020 at 02:09 AM The MyCaseBuilder tool is actually what I used to design the blueprint for my original pistol case. It's really handy, and if I could spare a bit more money I would have ordered one through them. But, the DIY route saved enough money that I could justify the purchases without catching grief, haha. Link to comment Share on other sites More sharing options...
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