I've cut a few Pelican case foam inserts and always mess them up. There are some companies that will laser cut the foam to your specs. Nice clean edges and a snug fit. It's not cheap but considering the value of what's inside, it's probably not that expensive.
High density foam seems to be a good way to go. It's easier to work with because it's more rigid. Also, it could last longer than traditional foam inserts.
“I predict future happiness for Americans, if they can prevent the government from wasting the labors of the people under the pretense of taking care of them.”
Thomas Jefferson
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