How to Cut Foam for a Pelican Case
Cutting your own Pelican case foam is doable with the right tools and some patience. Here is the method that gives the cleanest pockets – and when it is worth handing the job to a CNC machine instead.
Foam cutting tools you need
- Solid foam sized to your case (or the case’s original foam)
- A long, very sharp blade – a serrated bread knife, electric carving knife or a foam hot knife
- A white pencil or chalk for tracing on dark foam
- A tape measure and a straightedge
Step by step
Measure the interior
Measure length and width at the bottom of the base and the depth of the base and lid. See how to measure a case for replacement foam.
Lay out the gear on the foam
Leave at least 1" of foam between items and around the walls. Keep heavy items near the hinge side and toward the centre.
Trace each item
Trace straight down around each item, keeping the pencil vertical. Add a finger-pull notch where you will lift each item out.
Cut in shallow passes
Keep the blade vertical and cut the outline in several shallow passes rather than one deep one. Hot knives cut polyethylene foam cleanly – work in a ventilated space.
Remove the waste and set the depth
Pull out the centre and trim the pocket floor so each item sits just below the surface. Gluing a solid layer underneath gives a flat floor.
Test fit and close the lid
Everything should sit snug with the lid closed and not move when you shake the case.
When to have it CNC-cut instead
Hand cutting is slow and it is hard to keep the walls vertical. A CNC-cut insert makes more sense when:
- You are fitting expensive gear and cannot afford a loose pocket
- The layout has many small items – bits, magazines, lenses
- You need the same insert in more than one case
We cut custom Pelican case foam for the 1120 through the 1750 and the Vault series.
More guides
Rather have it cut for you? Custom foam by Pelican model
Each page lists the interior dimensions and what fits, and links to the ready-made RAGAR insert where one exists.
- Pelican 1200 custom foam insertInterior 9.31" x 7.13" x 4.12"
- Pelican 1400 custom foam insertInterior 11.81" x 8.87" x 5.18"
- Pelican 1500 custom foam insertInterior 16.75" x 11.18" x 6.12"
- Pelican 1510 custom foam insertInterior 19.75" x 11.00" x 7.60"
- Pelican 1550 custom foam insertInterior 18.63" x 14.18" x 7.72"
- Pelican 1600 custom foam insertInterior 21.51" x 16.54" x 7.99"
- Pelican 1610 custom foam insertInterior 21.78" x 16.69" x 10.62"
- Pelican 1650 custom foam insertInterior 28.57" x 17.52" x 10.65"
- Pelican 1700 custom foam insertInterior 35.75" x 13.50" x 5.25"
- Pelican 1750 custom foam insertInterior 50.50" x 13.50" x 5.25"
How to Cut Foam for a Pelican Case FAQ
What is the best tool to cut Pelican case foam?
A foam hot knife or an electric carving knife gives the cleanest walls. A long, very sharp serrated blade also works if you cut in shallow passes and keep it vertical.
Can I cut Pelican pick-and-pluck foam with a knife?
Yes. Cutting the outline with a blade instead of plucking the cubes gives a much tighter pocket.
How much foam should I leave between items?
Leave at least 1" between items and around the case walls so the foam has enough strength to hold everything in place.
Need foam that fits now?
Design a CNC-cut insert online in minutes, or shop RAGAR reconfigurable and pre-cut foam. Everything ships from Pomona, CA.
Pelican is a trademark of Pelican Products, Inc. RAGAR is not affiliated with or endorsed by these brands; names and model numbers are used only to describe compatibility.