For my upcoming PG hunt:
I had already purchased a Pelican/Redhead double rifle case for the trip, so I figured I would go with it. It did not have the pre-cut "pick-n-pluck" foam, so cutting was required. The foam set is $100 (plus shipping I guess), and as far as I could tell you have to buy the set, so I was trying not to screw it up. I did find a local source for foam replacement, but I don't have a price for the center piece only yet. This outfit does foam work for a couple of big case companies, it's an exact replacement type of foam.

I just finished cutting the foam in my Pelican case, and it was a learning experience. I had investigated a "hotknife" or wire cutter, but Pelican said not to use it, so I didn't. Tried a razor knife, but it's not capable of cutting all the way thru without compressing the foam. Improperly compressed or stretching while cutting leaves ugly evidence. Best tool? Chef's Knife! Dress the blade often with a V crock stick tool and "saw" without stretching the foam. Surprisingly easy to make straight cuts all the way through. Used a filet knife for corners. I'll post a photo or two. Anyway, the layout was the exciting part - drew the lines, changed my mind, drew some more then cut. Worked out well.





Nothing moves at all, plenty of room for the rifle and shotgun, scopes and bino's. Could add another item if I had to. Seems solid as a vault!

Anyway, I though other new guys might appreciate it.
78 days until departure....

I did find out that I can get sheets of the same type of foam, 1.5" thick, big enough to make two replacement pieces for $30 or so (from the local source). They called it 1490 style or type foam.

Now I can cut it for different items if I need to - just call and order the sheet!

Good job on the cutting I have the same set up and used what was called "hi density foam".

In addition I cut a spot for a fishing reel with a two piece rod tucked under the upper edge of foam.

I did the same thing with my pelican and it came out great. Even used the serated steak knife.

Used it 4 times already back and forth to Zim with NO problems what so ever.

What kind of double is that?

Try using an electric carving knife. Works great and cuts very neat straight lines and paterns.

Good job! I did the same thing. That's not a push feed Remington in that case is it as many here (not me) will tell you that you could be killed using a push feed rifle in Africa.

quote:

Originally posted by Steve H:
I did find out that I can get sheets of the same type of foam, 1.5" thick, big enough to make two replacement pieces for $30 or so (from the local source). They called it 1490 style or type foam.

Now I can cut it for different items if I need to - just call and order the sheet!

Steve, Would you be kind enough to PM me your source for the replacement foam..

Thanks.

Electric carving knife works great on foam as well as turkey.. Serated steak knife and Chef's bread knife also work well..

quote:

Originally posted by peashooter:
Try using an electric carving knife. Works great and cuts very neat straight lines and paterns.

The only person I ever saw use an electric knife for this purpose was my father, and he's been gone for over thirty years now. I thought it was an original idea with him - well, it was, but I see it's caught on. Nothing works better!

Yes, electric carving knife for the foam.

Call Pelican for new foam.

Your DR will be safer if broken down for transport.

Armbar.

quote:

Originally posted by MopaneMike:

quote:

Originally posted by Steve H:
I did find out that I can get sheets of the same type of foam, 1.5" thick, big enough to make two replacement pieces for $30 or so (from the local source). They called it 1490 style or type foam.

Now I can cut it for different items if I need to - just call and order the sheet!

Steve, Would you be kind enough to PM me your source for the replacement foam..

Thanks.

Steve, Could I also get the source for replacement foam. I just purchased my Pelican 1750 and used a hot wire cutter that I bought at a hobby store. It did an awful job. I should have stopped and used a knife. The wire cutter was made, apparently, for cutting styrofoam. My guns fit in nicely, but it turned out ugly.

I have the smaller Pelican Case for lighter weight.
I removed the Foam and I take my Rifles apart and put them in Soft Cases. My Scopes are wrapped in Bubble Wrap. TSA forbids Scopes in Carry On Luggage. I fill in with Clothing ect. bringing the Case Weight up to 48 LBS. Ammo goes in a Plastic Ammo Case inside checked luggage. Non TSA Locks on Gun Case. Copis of 4457 in Gun Case. 3 round trips with no problems.

If you want to see some amazing hard cases with expertly cut foam, and directions on how to build your own hot wire cutter, and sources for extra foam, go here.

Be warned. It is a 33 page thread!

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

As I prepare for surgery, what are your thoughts on the rifle bolts. I have always removed them, so I was planning on cutting out places for them.

I used a razor knife once...and it looked like a Lizzie Borden craft project!

The secret I think of using the hot wire cutter is to take time to make a posterboard template of your rifles silhouette and glue it to the middle layer of foam. Then use the hot wire to cut around the edge. Done right, the guns are a tight fit. So tight I glue the middle and bottom layers together so when you pull the rifles out the foam stays in place.

I took out the middle layer of foam and packed crap around the guns on one trip. Came home with two broken reticles! Luckily it happened on the trip home. Just too haphazard for me, considering you have no control what TSA may do.

Did the surgery on my 1750 center foam last night. Followed instructions--traced the outline of the rifle, then cut 2mm inside with the electric knife. Perfect. Still haven't decided whether to remove the bolt and cut a spot for it. One thing for sure, once the surgery is done, it's for that rifle only.

VFR1, I'd be real interested to hear what you decide about the bolt. I'm at the same point and wondering if just slicing the foam the length of the bolt with another slice for the handle would work better than trying to do a cut out.

Most people on AR are very much in favor of removing the bolt from the rifle. I always do and there has never been any problem. I do however use a Tuffpak as opposed to other cases on the market.

That's one of the cool things about the TP, never any foam cutting, fitting and worrying. Just pop the rifle in a good soft case, (you will need a soft case anyway in Africa) place in TP, lock and go. Quite simple and doesn't look like a guncase to boot.

Larry Sellers
SCI Life Member

Larry, I'm sure I'll end up with a TuffPac one day, but I have a Pelican now and for this year, a Tuffpac is roughly the trophy fee on a warthog, or a couple of impala, or a bushpig.......

Also, its a long winter in Colorado and doing a little surgery on some foam really takes the edge off a 5 day blizzard. Beats shooting holes in your freezer

Finally, on my last few safaris, the Tuffpac was way more prevalent than traditional cases. So much for not looking like a guncase anymore. They are really taking over the market!

Gazi - I know what you mean by the 5-day blizzard thing. Kinda been the same down here in New Mexico at 8,500 elevation. Sometimes you can find a used Tuffpack if someone is upgrading to a different size or model. Good luck with the surgery!!

Gun cases, I thought there were just a lot of golfers out there?

Larry Sellers
SCI Life Member

quote:

Originally posted by Gazi:
Larry, I'm sure I'll end up with a TuffPac one day, but I have a Pelican now and for this year, a Tuffpac is roughly the trophy fee on a warthog, or a couple of impala, or a bushpig.......

Also, its a long winter in Colorado and doing a little surgery on some foam really takes the edge off a 5 day blizzard. Beats shooting holes in your freezer

Finally, on my last few safaris, the Tuffpac was way more prevalent than traditional cases. So much for not looking like a guncase anymore. They are really taking over the market!

I have a toughpak and a Pelican.There are advantages to each and reasons to take one on a tripover the other.

Cant beat a Tuffpak for travel but that Pelican is a beast! Like the others I have extra foam sheets cut out for different rifles.

Pushfeed Remingtons
AR 15
AR 10

That Pelican is a great case. I like all their cases all the way down to the small one I sue for ammo casr\e.

Thanks Wendell. Did you make cutouts for your bolts or leave them in the rifle?

I cut mine out with the bolts in the rifles not even thinking about possibly needing to remove them. I wonder if it would be better to just place the bolts in the case and close it instead of cutting out separate spots. I guess I'll just have to try it.

Ckemp - I would advise to wrap the bolts in bubble wrap or foam and then put them in the case. I wouldn't want and unwrapped bolt floating around in the case to damage anything metal or wood it came in contact with.

Just curious???? What do you guys that take non Tuffpack cases do for a soft case for your African hunt??

Larry Sellers
SCI Life Member

quote:

Originally posted by Ckemp:
I cut mine out with the bolts in the rifles not even thinking about possibly needing to remove them. I wonder if it would be better to just place the bolts in the case and close it instead of cutting out separate spots. I guess I'll just have to try it.

Larry, I just put my filson soft case in my other checked baggage (a filson large duffle).

I wrap my soft case around the inside of my luggage and pack everything else inside of it. Kind of an extra padded layer inside a soft case.

Gazi,

I don't use a Pelican but my ICC case is the same idea. I just make a slice for all my small items including the bolts. Secures them nicely.

Mark

Thanks Mark, that's what I needed to know.