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3 Tips for Cutting Foam for a Custom Gun Case from LaRue Tactical

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This month many of us received the first issue of the “LaRue Accuracy Report” in the mail. The report is LaRue Tactical’s new “digest for the discriminating rifleman,” as Mark LaRue puts it. Boiled-down, the publication is an eighty-eight page seasonal catalogue (translation: catalog) full of product images and info, along with a few short articles related to rifles:

Max Point Blank Range Explained, by Todd Hodnett

The Layman’s Guide to Parallax, by Pete Gould

DIY Custom Sniper Case, by LaRue Tactical

Now, I could look at LaRue catalogs catalogues all damn day long – their products are dead sexy – but being a life-long case-junkie I was more interested in their advice about how to build a sniper case.

Pages seventy-eight and seventy-nine of LaRue Tactical’s “LaRue Accuracy Report” outline a premium option for creating a custom foam case.

My hat’s off to LaRue for their extremely concise and informative article titled, “DIY Custom Sniper Case,” or “Make Your Own Custom Sniper Case: Cutting Gun Case Foam Like A Pro,” depending on where you look in the publication.

The most impressive aspect of the piece is the detailed instruction LaRue provides for how to make a hot wire foam cutter. The accompanying diagram and photos, while small, help illustrate the narrative exceptionally well. The specifications required to build a cutter are provided clearly and purposefully.

Not only does the article cover the wire cutter, it thoroughly covers one process for tracing your items onto the foam.

To obtain a copy of the LaRue Accuracy Report, send an email to tim@larue.com with the subject, “Accuracy Report Request – TTAG Reader,” and include your mailing information in the email.

If you’re not into building electrical circuits and working with hot wires, but still want to cut foam, you have three great alternative tools you can use:

Static Knife: My go-to knife is a Cutco Fisherman’s Friend fillet knife (above) because it is thin and has an adjustable length blade. Serrated knives also work but do not cut as cleanly.

Electric Knife: Some folks prefer an electric fillet knife or bread cutter. I have used them both free-hand and mounted to a workbench to operate like a table saw or band saw.

• Band Saw: A band saw will create a very nice, clean cut. However, because the blade has no end you will need to cut through the outside edge of the foam, or from one area to other area once you are inside the foam, then glue the seams together at the end.

One of my current projects is a custom case (above) to house a G20C with accompanying kit. The case is divided into three levels, the lower of which is hand-cut to fit the “hard goods” using my Cutco fillet knife. It’s not perfect, but it’s going to get beat to hell so I will get another stab at perfection (literally).

As you prepare for your next custom case project, take into account these three pieces of advice:

1. Have a specific purpose and plan, but prepare to be flexible

2. Choose your case based on your items, not your items based on your case

3. Take your time at the workbench

Good luck and don’t be afraid to make a mistake; the price of new foam is a small one to pay for perfection.

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