Pelican gun case and foam cutting

[sam700]

I picked up a Pelacan gun case a while ago and was wondering if you are supposed to cut all the way through the middle layer of foam or only cut 1/2" into the foam. Cutting all the way through the middle layer while leaving the others intact would be easier, but allow the gun some wiggle room. On the other hand, cutting only part way through the foam would be difficult do do cleanly.

Also, if I leave the foam uncut till I have time to work on it, is there any worry about damaging the hinges. I have to stand on it to close it when the foam is uncut.

 

[JWarren]

I picked up a Pelacan gun case a while ago and was wondering if you are supposed to cut all the way through the middle layer of foam or only cut 1/2" into the foam.

You cut all the way through the center foam.

Cutting all the way through the middle layer while leaving the others intact would be easier, but allow the gun some wiggle room. On the other hand, cutting only part way through the foam would be difficult do do cleanly.

There is no set way, but 99.9% cut through the center foam completely. Be careful, it isn't easy to get it right-- even cutting through it completely.


Read this link. It tells how to cut it cleanly:

http://www.ar15.com/forums/topic.html?b=3&f=4&t=292695&page=1

Also, if I leave the foam uncut till I have time to work on it, is there any worry about damaging the hinges. I have to stand on it to close it when the foam is uncut.

No harm to the case.


-- John

 

[gcrookston]

They come with 3 layers now? I have several, but haven't bought a new one for about 10 years now. One little trick I did do on the old 2 layers, was after cutting out my rifles, I glued the pieces together with rubber cement.

 

[JWarren]

Yep, my 5160 is three layer.

HOWEVER....

I just learned that the foam is open cell foam-- meaning that it CAN hold moisture. This came directly from Pelican. Their solution? Put silica packs in it.... Uhm... no. I didn't pay $200 bucks to have that little detail missed. Closed-Cell foam ain't that expensive.

I plan on replacing ALL THREE pieces of my foam with closed-cell foam.



-- John

 

[hksw]

Cut all the way through the center foam. With the part that gets cut out, cut it in half (thickness) or however deep you need it to be and put one half of it back into the cutout when you put the foam back into the case.

 

[Claude Clay]

freeze it overnight and cut/shape with any good serrated knife. do your layout before freezing. hot wire is the best--but for infrequent or one-off projects, freezing works. rifle size pieces in your (or a friends) chest freezer. the thin board you use in the freezer to keep the foam flat is the same one you do the cutting on. if it starts to thaw, refreeze and finish the next day. to adjust the plugs for thickness; compress and use scissors or refreeze and slice.

 

[gpr]

foam

an electric knife makes it easy to work with foam....just don't let the wife see you doing it...gpr

 

[gcrookston]

+1 for the electric knife. Also remember, scope to the top, action facing you.

 

[aztrader]

found this tool

Anyone know anything about this tool?

http://www.amazon.com/Uchida-Of-Ame..._m=ATVPDKIKX0DER&pf_rd_r=1R1YR21YQFDW8J33KPNY

 

[edelbrock]

found this tool
Anyone know anything about this tool?

http://www.amazon.com/Uchida-Of-Amer...1YQFDW8J33KPNY

Nope. But that seems expensive for something that just cuts foam.

 

[aubie515]

You can make your own "hot knife."

http://www.ar15.com/forums/topic.html?b=3&f=4&t=292695

I'd rather spend $50 and have it look professional than to buy a cheap electric knife and have it look like a 5 year old went to town on my rifle cases.

 

[DRYHUMOR]

A router or rotozip tool would work also.

 

[Smith357]

I use a razor sharp 6" flexible fillet knife, it must be razor sharp, if you can't shave with it it's too dull.

 

[brian3962]

I didn't want to cut out the foam that came with my pelican 1750 so I came up with a way to trim the foam. I made a single cut in a fine tooth band saw blade then stretched it between two 1x2's that I secured to a piece of plywood. So basically I ended up trimming the foam down by 11/16". I then took my foam and slowly slid it back and fourth on the band saw blade making sure it stayed flush against the plywood. It took a couple minutes to
cut all the way through it, but it couldn't have turned out better. I ended up with a nice clean cut and now my rifles/pistols/shotguns all fit tight enough to keep them secure and now I don't have to almost burst a blood vessel in my head trying to close the cover...