I'd like to get some thoughts about gun case foam. I have a couple of Plano Field Locker rifle cases, but I have too many rifles to have custom cut foam made for each of my rifles. So I was thinking about getting some thinner foam to put into the cases, such that when the case is closed there would be roughly about an inch +/- of space between the two pieces of foam. This would just squeeze the rifles in place to keep them secure while I drive to and from the range. I was looking around at carolinacustomfoam.com and it looks like their convoluted foam may be ideal for this. Anybody have cases set up like this?

That's pretty much the std. way on any number of factory plastic cases. What's your concern?

Not really concerned, just curious how much space I should leave between the foam in the lid and the foam in the base to get a good "sqeeze" on the gun without distorting the case. The Plano cases came with solid foam in the base and were meant to be cut in the shape of the gun to hold it in position.

Even when I put two guns in my SKB case and there isn't ANY "space", the guns can shift a little.
I wouldn't leave any.
Yes, it's very tight and I have to press firmly to latch. No Big Deal.
The foam is supposed to compress the gun tightly. One inch of space IMO is too much.

ditto on the no space,

I use some hard cases for packing and transporting to and from gunshows,
have a couple that have space, or just a bit loose, and they firearms always slip inside them,

I've been looking for gun case foam myself!

I've got a 4 56x18x6" Pelican cases I bought from our State Surplus. They appear to be what Pelican calles their Protector Serise, which have "O" ring gaskets and pressure valves. They once held fixed leg tripods and iPads, the cases may have been more expensive than the contents(no expense spared with tax dollars!).

I'd like to repurpose them as rifle cases but the foam has been cut so that it's not compatible to a rifle. I've searched a bit but haven't found a suitable type of dense foam ... at least at a reasonable price (Pelican wanted $200 for each case)

... any help/suggestions?

Check out carolinacustomfoam.com.

Wow!

Thanks marc308 ... My google-fu must be out of whack because after seeing this thread I did some more "searching" and still didn't find that company!

Try Cobra Foam inserts. Good to go! Pre cut for cases listed, or custom order. Whichever you prefer.

Foamerica dot com has a full line of Pelican stuff and they also have replacement foam pieces to fit each case.

I've done more looking at the case" and I can't find a name anywhere except the pressure release valve says SKB, but no model number. There is a label on one of the 4 which says Custom Cases and Foam ... has California address and 877 phone number, called and they are still in business but haven't been able to get a human yet ... see what they say.

I recall the November or December American Rifleman had a nice article on this company:

https://www.mycasebuilder.com/...and-rifle-cases.html

I hated the pluck and suck foam I had. I just went to my local furniture guy and he had tons of choices. I got one that felt about the right density and used that. Has been working for quite some time.