How to: Cutting Your Own Foam

March 29, 2018

How to: Cutting Your Own Foam

The Pick ‘N' Pluck foam insert is by far the easiest and most often used method to produce this result for your Pelican™ case. These pre-scored pluck foam pieces come in different layer thicknesses. Depending on the size of the case there may be anywhere from one to six or seven foam layers in a case. There is typically one solid piece on the bottom of these cases which should never be cut through. 

Step 1 - Lay It Out:

Pick N Pluck - Step One - Lay it out

Decide the best layout for your items. Depending on how fragile each of the individual pieces are - try and leave at least 1” between each piece. For delicate pieces 1 ½” -2” is advisable. Consider creating a catch-all cutout for things like wires or clips to save on space.

Step 2 - Trace It

Pick N Pluck - Step One - Lay it out

Using a sharpie or even chalk (some people use toothpicks as well) trace your equipment making sure you leave enough space between each piece. Some people even use toothpicks  Any fragile pieces should be placed away from the sides.

Step 3 - Pluck It

Pick N Pluck - Step 3 - Pluck it!

Remove your items and begin manually plucking the pieces inside the traced areas. If you're feeling really fancy you can use an Exacto knife type blade to cut more exact shapes & contours.

Since most items aren't flat, you'll probably want to cut the pieces to various depths to better fit but that is up to you. 

After you are done plucking the foam, use the removed foam to lay back down so that the height of your items will sit almost flush to the top of the foam piece. 

Step 4 - Place Items Back

Pick N Pluck - Step 4 - Add Items Back Into Case

Once you are done with the foam removal and leveling, place your items back into the foam and adjust as needed. A snug fit is the best fit. You don't want your items to be moving around during transit. To remove the residual chalk lines, wipe away with a damp cloth.

And that's it! Easy peasy. 

1500 Yellow Pelican Air Case - Pick N Pluck - Camera

Step 5 - Glue it (Optional)

If you find you’ve made a mistake or have any loose areas, cut off the corresponding piece from cutout and glue back to wall with spray contact adhesive made for polyester foam. We suggest 3M™ Super 77 Spray Adhesive and follow the application directions on the spray can. 


Case we used for demonstration:

Foam we used for demonstration:

Replacement foam for a Pelican case:

Pelican case accessories:


Need any help? 

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