Wouldn't an eggshell matress pad work in this situation. You can get different widths, thicknesses, and sizes of this stuff. It's cheap at Wally world. Hope this helps. If you try it let us know how it works out for you. Be safe.
Go to Academy...in your area it might be called Dick's or Jumbo, or Oshman's or something else...it would be a sporting goods superstore...back in the camping stuff they have foam in several thicknesses in sheets of standard size...just cut to fit.
I have purchased foam from foamorder.com as replacement foam for several Pelican cases I bought online. You can choose from a wide variety of foam types as well as custom order the dimensions you need. IIRC, I ordered from the "conventional" foam section. The prices were not at all bad and shipping costs were reasonable.
if you can fing some one in your town that reupholsters furniture, or better yet does custom car interiors (they usually use a more dense foam than furniture upholsterers).you can get just about any type and density of foam you would like. i made a shot gun case for a freind and got my foam from the local upholstry shop. i used a smooth, soft sheet for the gun to lay on and a very rigid layer on top of that ,cut to the gun's profile. the rigid top layer held the gun in place real firmly and the soft layer cushioned the whole case. i then covered it with red velour. the rigid layer was also allot easier to cover because it held it's shape real good when you had to pull the velour ab bit to get it tight around corners. i used 3-m spray adhesive for the whole project. this was all suggested by the upholsterer and it worked out great. some of the foam is fairly expensive, so ask if he/she has any remnants from other jobs that might work.
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