Custom case inserts are the most effective way to keep items such as electronics, guns, and breakables safe while in transit or storage. However, if you don't have the time or money to invest in custom foam inserts, you may be able to make your own. Here are three ideas to help you:
1. Plastic bags and packaging peanuts
The fastest and easiest way to make your own foam inserts is with a few plastic freezer bags and some packaging peanuts. Simply, fill the plastic bags with packaging peanuts, and surround the items you are trying to protect with these bags.
This is neater than using packaging peanuts on their own, but if you've got more time to work with, you may want to try one of the other two methods. They offer a more custom foam fit.
2. Sheets of foam and a small knife
If you have sheets or thick slabs of foam, you can use those to create your own custom foam inserts. Place the item or items you want to protect on the piece of foam. Trace around it, and remove the object.
If you are using several sheets of foam, trace out the same shape on one piece after another. Stop when you've cut through enough pieces so that you can stack them to the same depth as your object.
Place a final piece of uncut foam on the bottom of the pile of cut foam. If you like, you can glue the sheets of foam together for extra support. Finally, place the foam insert in a box and nestle your item or items in the holes you cut out. Then, place a final piece of foam or two on the top and seal the box.
3. Custom foam inserts with spray foam
Finally, try making your own custom foam inserts with expanding foam. Place the items you want to protect in a box and cover them with a thin t-shirt or tea towel. Spray expanding foam insulation all over the cloth until it fills the box. Wait until the foam dries.
Tip the box upside down so that the foam falls out. When you remove the shirt, the foam should have molded to the shape of the items under your shirt and now, you have an almost perfect homemade custom foam insert. If you like, you can make a second one, and then, you have two pieces of foam to protect your items when you pack them away.