How to Cut Pelican Case Foam for a Rifle Without an Electric Knife!

Link to the Havalon knife I used to cut the foam:
amzn.to/3niILJX
If you recently purchased a Pelican 1750 rifle case and you're going to be cutting out the foam to fit your gun, you may find that the directions and most other videos tell you that an electric knife is necessary. In this video I'll show you how to do it a much easier way.

[@stevenm2062]

It disappoints me when he didn’t aim the gun shaped cutout of foam

[@canespugnaces2126]

Then he would be aiming a California compliant weapon around 🤣 🤣

[@bchappy5460]

😂🤣

[@tylerburnham17]

I literally just cut one out 5 minutes ago and had to right away aim it around lol

[@andoriannationalist3738]

Safety first. That would be assault. Ask the 6 year old who got expelled for pointing his fingers at another student and said “bang!”

[@TheOpbyou]

Ditto

[@ulrichpieplow3858]

nice tutorial! One additional consideration: The foam piece is somewhat smaller than the actual case, leaving a gap between foam and case. Once you cut the foam, this space creates additional room between rifle and foam. It was said in the video but just to emphasize: keep your marker really close to the rifle, otherwise you quickly end up with too much wiggle room!

[@TubTsovPhajEj]

I recently did my foam with a Havalon knife as well too and I can't believe it does an amazing job cutting out the foam really well. My rifle sits perfectly in the case.

[@jlo5134]

To date, I've watched roughly 20 videos on this very subject matter. And while many of them are informative and good, your precision, technique, and outcome is by far the best! I think I've watched your video about seven times now (not creepy at all, right?) 😆 As someone who is also a perfectionist, if not OCD, I can appreciate your approach and care. Nice work!

[@backfire]

Thank you!

[@joeypruitt6304]

I'm about 5 videos in on the same process of finding the best technique. This comment may save me from watching too many more. lol

[@ArkansasBadBoy]

@josephroach9793 I used to use the ones with the textured handle and you are correct. I switched to the Buckingham model 7091G and prefer it. That hook is like magic for a multitude of things.

[@qunningStunts]

Your OCD makes my OCD happy. I've been trying to think of what has a long exacto/scalpel blade...thank you for reminding me that these skinning knives are a thing!

[@EarthnikNews]

I do commend you on the cleanliness and accuracy of your cuts. Much better than butchering the foam with an electric backhoe. I us a Hotwire cutter for all my cases. This assures that everything is exactly 90°. I need someone to help me video the process sometime. The Hotwire thing takes a knack, but it looks like a professional CAD cut.

[@philhardwick100]

The first time I saw that rifle in the store I was blown away by how cool it looked. Wouldn’t have been able to stop myself from buying it except it was in a caliber that I didn’t need.

[@adamnylund9864]

Thanks for the video. I watched several of these before I cut my first case foam. I recently did a second gun case and used a jigsaw with just a standard wood blade. It cut beautifully! The jigsaw was extremely easy to make both straight lines and even tight curves. I highly, highly suggest you try it on your next one. I promise you won’t go back!

[@canespugnaces2126]

I just got a case in yesterday and bought an electric knife on my way home to cut it with. About halfway through i just started using my pocket knife to cut it. It was cleaner and I was able to trim to fit a lot better. I think I'm going to have to get a replacement foam insert and try at it again to make it look better. Live and learn.

[@sambubu4195]

I stumbled upon the BEST and cheapest way to cut foam: use a box cutter/razor knife and heat the blade with a propane torch or even bic lighter - no need to get the blade red hot. Cuts better than a hot knife through butter

[@kevinkelley3657]

Another very good method is to trace the outline like you did, then cut the outline with a box cutter, and then work a serrated bread knife completely through in one spot, and then use the bread knife to finsih the outline. The serrated knife will cut the thick foam very easily, and if you keep it at 90 degrees in relation to the surface of the foam, the cut will be very straight and very smooth.

[@ferrari340gt]

Does a bread knife work well in sharp angles as well? Or just stick to a box cutter for those sections?

[@jessedaniel4449]

Ordered this knife based off your review. I hope I have good success.

[@ThatOneGuyWhoLostHisHandle]

Yeah fr I just ordered it should I cancel?

[@jessedaniel4449]

It worked like a champ

[@arnellespassion6206]

Thank you for taking the time to make this post. Also, thank you for sharing this method of cutting the foam. I will adopt your method if you do not mind me doing so...!

[@larrysweetser4198]

SN Up for TSA = "Thousands Standing Around" & All the heavy CG items down by the wheels so easy (r) to move.

[@DaysOffCustom]

Nice! I didn’t own a Havalon until I saw your video and checked it out on Amazon.

[@jasonmakos]

Nice, I have watched similar videos and this one looks the best. I got my case but have not cut the foam yet. I did see some videos were after they cut they sprayed the foam with a product I can’t recall the name but it protects the edges. If that is something you do I would love to see a video of it. I really enjoy the videos and keep up the good work.

[@nickflores9775]

It is called plastidip. Just make sure you let it dry out and dont put to many coats

[@joshuaguard8097]

Utility knife with break off blades work really well. If you can use a hot wire cutting on a tables set up for super clean cuts.

[@michaela.7544]

You are a self-made guy ! Great job man!

[@ilpostinomotociclista270]

From another channel, as the host held up the foam he cut out: “We have our California approved ar15 here.” 😂 Nice vide. Thank you.

[@sstevenwayne1]

a sharp fillet knife works well also .

[@gilbertdelgado6703]

Excellent job cutting that foam. I have tried a couple of different methods, including making an electric wire cutter which worked good but I was not all that impressed with the results. It is, in all actuality, my fault in how the results came out. I am going to get one of the havalon knives and give that a try.

[@Helcat338]

Excellent and Informative Tutorial Outstanding Job

[@americanpatriot7939]

Looks great ! Best I've seen so far

[@brucenelson6286]

Great video!! Looks like kaizen foam, an easy to use layered foam used for organizing, protecting tools, firearms, etc.

[@FactsMattersUSA]

Great video. The pros use Hotwire for quick precision cuts.

[@richardwalker68]

Thank Jim, just about to buy some foam for my case.

[@donaldwagner6012]

Very nice getting ready to do the same and was going to use the electric knife but not now.

[@martinz.4852]

Screw the Turkey knife. Great job and great video!

[@aust1nku]

I watched this but still went with an electric knife. I now have another foam set and a Havalon knife on the way because I messed up

[@backfire]

Haha. Oh man. Funny post but I’m sorry that happened to you!

[@madthevillain]

How did the knife approach work out for you?

[@zingo_man]

Big like because I already have that knife at home

[@King_drew]

Awesome tutorial!!

[@ethanperks372]

I'm a new subscriber! I'm really enjoying your vids! So Thanks!!!

[@bullrun1]

did you cut it so the gun fits in with the serial number up so TSA can clearly see without having to remove gun from foam? (saw this on another an thought good idea)

[@williamhunter658]

Great video!!! One question for you though, is there another layer of foam under the cut piece?

[@Ashurus]

You vacuum the carpet where the couch is going to go, because how often if you do, do you clean under it? Clean it before placing since it won't be cleaned again, probably ever.

[@NC_Fisher_Guy]

6:44 that's a pretty flaccid looking gun ya got there Jim.

[@PoliticallyInsensitive]

I have a Nanuk 995 and cut the foam with my pocket knife. Yeah i butchered it but the only time I'll use the cutout (and quite possibly the case itself) is if i fly with it or travel a long distance for a class by car. The the foam inside the lid puts enough pressure on it to keep it from moving.

[@john-paulsilke893]

Still enough room for a short barrel shotgun, at least if you live in Canada. Of course if you live in the USA you can throw your favourite .357 or .44 Magnum revolver for a poop gun in case you get placed on the menu. 😊

[@ChrisB-xs4un]

A very simple exacto knife from the dollar store works just fine. No need to get complicated. Sharper blade than any skinning knife you have.

[@philbaker29]

You ever try to cut 2" of foam with a 1/2" exacto knife? Sure, it can be done if you don't mind it looking like your kids botched art project.

[@Ultimatereloader]

Nice!

[@surfearth1]

Keep the inserts and use the other uncut foam pad to make a second configuration.

[@derrickrr5516]

Use a frickin laser Mr. Bigglesworth!

[@756766]

Awesome work

[@Golden6stroke]

If you think about it you could that one case for all your guns just use different foams cutouts

[@Scorpio-fi1ir]

Great video. Got to the point.

[@scottgreen6369]

An electric knife was able to cut through the foam with ease, but it tears the foam rather cut it (at certain points) which looks awful on the backside. This video shows the best way to do it w/ clean edges.

[@lanceschul]

Jim, have you ever checked out or reviewed the Nanuk gun cases? They look pretty solid but I just found out they exist and am trying to do some research.

[@capitaldd5840]

What's the story Inn the dive helmet behind ya on the shelf.......... Great video... good info to know

[@joshroberts8881]

Do not waste your time, I’m stopping in the middle of doing this method just to comment this. I ordered this exact knife and it’s not even long enough to cut through the thick foam. Yes it’s extremely sharp but if it’s not even longer than the foam, you’re forced to start sawing at it. I am now having to purchase new foam and use the electric knife.

[@shanehoward9756]

I noticed a lot of other videos have the rifle the other way, with the scope next to hinges. So if closed and transported this way, the rifle would be upside down. I’m guessing the way you did it would be the best way. Would you think it makes a big difference?

[@inalaska1709]

Depends on how you carry the case. If you only use it by dragging it with the wheels probably not, but if you, or more importantly the airlines, grab it by the middle handle, it puts the weight of the rifle on the scope.

[@LRS7B]

Knowing the Sharpie pen would be on the underside of the foam would play havoc with my OCD *#OCDLife* 🙄🙄

[@joneaton7793]

You mean CDO?.... Its in alphabetical order the way it should be...

[@sillyshrapnel]

was this pick and pull foam?

[@lucuix9901]

What length is your rifle. Mine is 47 1/2''. They say the 1750 fits up to 48 but Im assuming that means with space still

[@jayc4562]

Use a hacksaw blade. Upholsterers use them to cut foam.

[@gerryballuta]

Thank you

[@NC_Fisher_Guy]

"Trace it like a dead body after you've killed someone" are we not going to talk about that? Okay.

[@captainjoesanglingadventur4894]

So what does your $4,000 gun actually rest on the case itself or do you have another super thin piece of foam under the cut out?

[@daveevans7151]

Yes, those cases have layered foam. One is the cutting foam, which you saw him cut, and that rests on another full layer. So it ends up like a sandwich…foam on top and bottom, and rifle in the middle. Hope that helps!

[@thenamelessyee]

Would plasti dip hurt any thing on a case like this

[@gregisaacs7091]

I'm wondering if you've plasti-dipped it yet? That may be your next video.

[@benb7727]

An .89 cent skinny snap blade works too

[@euroroadtrip2010]

What brand knife

[@russellhansen7004]

Can you show a sako A7 30-06

[@larrycoonrod5563]

So you can afford the Browning A-Bolt, scope and Pelican case but not an electric knife?

[@yamahschector]

Why does everyone take the bolt out. We have an ar style shotgun

[@HiddenCreekHomestead]

So there’s no pressure on the bolt handle

[@anton1949]

Next: How to eat spaghetti without a fork.

[@christiansanchez8959]

Women sowing scissors 😂

[@jamesfreeman6025]

If you are cutting a piece of 1" foam it works good. The blade on the Havalon knife is to short to cut completely through a piece of 2" foam without using a sawing type method. It does not go through the foam as easy as he says it does. I would not recommend that knife for the job.

[@muchohucho]

Why does it even have to be cut perfectly contoured? Could want to use it for different rifles.

[@joeplanter7959]

Who else is watching this after they already used the electric knife method...

[@bikeboy0012]

$5 says that you switch calibers when you realize you don't need to shoot a cannon to kill...just as so many do

[@anonymous_friend]

.243 all day, everyday

[@BWEEZY8023]

Simple

[@nito5809]

0:40 lol have the same thing

[@4estrnr472]

Holy cow my foam looks terrible oh well lol

[@TheGreasemonkey220]

@4:05 what you trying to tell us here bud??? 🤔🤔🤔

[@trailguy]

Just hone it, I doubt you need to grind your bevel.

[@jackmehoff6557]

stop with the side comments

[@brockskarsgard8137]

28 Nosler on a hog hunt? Making sausage before making sausage….

[@JohnDoe-zg6fn]

👍🏽👍🏽👍🏽👍🏽👍🏽

[@AsphaltCowboy.]

Brag way to much