Okay, I'm moving at the end of november, and I want to make new cases for all my airsofts since the boxes got thrown out. I have 6-7 sidearms, one shotgun, and 4-5 rifles. Now, these are going to have to be low budget, since I can't afford to BUY the materials and wher I work has lots of unused boards lying around. (I've asked, they don't care if I used any of it.)
They're going to be latched on the front, OD green, and have a dark grey USCM symbol on the lid.

Now for the questions.
1.I'm thinking of getting the foam stuff for the "cut-out" look, but don't know what to get.. Alternatively, what else would look acceptable?
2.In one of the corners on the lid, I would like to have weapon type, a serial #, etc. but I don't know how to make it look "official". Any ideas?
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Fear is funny. You wouldn't think you could jump five inches using only your ass as a propulsion device..

I haven't done this myself yet as everything I use is just off the shelf items. But, if I were to do it...

I'd use two layers of waffle foam (the black/grey stuff if you can get it) for the top (lid) layer and the very bottom layer. Then I'd use some closed cell foam (black) for the middle layer, and cut the shapes to fit my guns.

But that's just me. Some one here made a nice pulse rifle crate and used foam with a camo material cover over the foam. It looked pretty nice as well.

In fact, you might even be able to use the camo cloth over some standard white chair/bed mat foam. You'd start with... say 1/4" thick piece of plywood as a base. Making sure it fits inside of your crate/gun box.

You'd then use some sort of foam material for the bottom layer, probably a 1.5" chair seat foam. Then cut your gun shapes out of 4" thick white bed/bench seat foam. Then lay your cloth over the 4" thick foam, pressing it into every corner in your cutouts and using a staple gun, staple the foam down into the plywood base, through the 1.5" bottom cusion.

Sounds complex, but it really Isn't. Just time consuming planning everything out. I did something similar while making an "ejection seat" for an airsoft game. The wooden frame of the seat was pretty rough but the foam seat itself was pretty sweet.

Russ



"Time has little to do with infinity and jelly doughnuts."

Cool, thanks. ^_^
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Fear is funny. You wouldn't think you could jump five inches using only your ass as a propulsion device..

oh cool, tyvm for the link. ^^

anyone got any ideas on how I should write up the contents onto the lid?
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Fear is funny. You wouldn't think you could jump five inches using only your ass as a propulsion device..

Another method of crating guns is to use the skeleton approach. Provide blocking within the box to support the gun hard points. Don't fill the crate with foam but only use it at support points or try leather for the classic look.

This method looks really good if you have multiple to pack in the same crate.
Sample crate