I have a few gun cases and I'd like to find some flat replacement foam. Not the egg-crate looking foam, but the flat foam because I would like to make cutouts for my guns to fit in. Does anybody know where I can purchase foam in general sizes online or even better, is there a business I could find locally (Brownsville, bottom tip of TX) that makes/supplies foam in various sizes?

Thanks for your help.

Go to your local Upholstery Shop (auto), they should have
just the Ticket. Color choices as well as density / thickness.
Cut your pattern with one of those electric carving knives, or
a hot knife. A razor knife can also be used, but will be a
rougher cut, not as clean of a cut.
For a small fee, I'm sure the Upholstery shop will even do
the cutting and fitting for you.

"But Hey ~~~~ What do I Know?"

ya here awhile back i was looking for some of that also.

if i remember correct i found it at wal-mart.

good luck, lets see some pictures when you get it done.

uline.com

cushioning section : http://www.uline.com/cls_05/Cushioning-Foam

Good tip on the upholstery shop, I'll check that out.

I'll give Walmart a try too.

Thanks

You can get better quality at the upholstery shops.

Hobby Lobby? Upholstery shot might be a little pricy... Or it could be free, who knows?

Neither Hobby Lobby or Michaels carry that thick, already checked.

Hmmm... Would have lost that bet, GLC. Did they have any? If so, I guess you could stack and glue it but it wouldn't be as clean as one solid piece.

The RRA case I got with the AR is a piece of junk. That's why this thread interests me. I've been wantind to do something similar...

Try this....pick-n-pack foam

http://www.uline.com/BL_873/Pick-And-Pack-Foam

Wife says try the fabric store - Hancock Fabric.

hell of a name but yes real store lol

I appreciate all the replies, and I've been spending the last hour or so researching it a little bit. For those interested, I'll share what I found.

First off, the pick and pack foam, while convenient, won't give you that clean look.

Second, I've found that if you plan on storing a gun in a case for a long period of time, you don't want to use foam that will retain/absorb moisture. It's best to use a marine grade foam like Polyethylene. Here is a link to a good site where you can buy it in big sheets and various thickness (you'll want a thin sheet, or a cutout, of foam to lay on the bottom to protect your gun/attatchments:

Link to Polyethylene foam

Also, for that bottom layer, you could use a different color to highlight the outline of the missing item (yes, I get anal about my projects sometimes). I know airplane mechanics do this alot so they can readily notice if a tool is missing from there toolbox. And it looks good.

Link to Minicel foam

Lastly, you can cut it out a number of ways, but here is a link to a write-up by a guy who made a hot wire cutter. He's got a clean looking gun case.

Hot wire write up

And I'll throw in a pic of my toolbox that I cut foam for my sockets. I was bored and it took forever, but damn, it sounds sweet to open and close that drawer and there's no rattle.....and stuff stays put and I know exactly where every socket is when I need it.

And for those of you further interested, but don't want to build a hot wire setup yourself, there is this site:

http://hotwirefoamfactory.com/home.php

That has to be the neatest, cleanest toolbox I have seen in a long time.

Thanks Lots of questions answered on this thread.