Pelican 1650 alternative foam inserts?

[clemmb]

I bought a Pelican 1650 without foam. Its basically the size of a large suitcase, with dimensions at 62" total so it is allowed as checked baggage without extra fees, albeit heavy empty.

I figured I could get foam elsewhere, aftermarket. Does anyone know what the alternatives are?

I didn't buy foam as I know it will likely be a multi-usage case, so the Pelican foam would be wasteful. I was curious what other creative ideas people have had for this sort of thing.

I have the Pelican 1600. At Hobbie Lobby I purchase the thickest foam they have. It is only half as thick as the case is deep so I double layer it. Glue it together. I lay my gear down the way I want it and draw an outline with a sharpie. Using a sharp knife I cut out the areas for each piece.

IMG_0766 by clemmb60, on Flickr