I have a Pelican-like box that I've used to create a fairly nondescript car/truck gun box from for my AR-15 pistol. The pick & pluck foam isn't tight enough to support the loaded magazines I've got in the upper half and just falls out when I open it. I'm thinking spray on glue, but figured I'd ask as I'm sure some of you have run into similar problems. I have lots of different glues to choose from in my shop, just wondering which is the best way to go.

Dap weldwood?? We used to glue foam jet ski mats down with that stuff and it holds well but you have to coat both surfaces and wait for them to get tacky.

I did something recently and used hot glue gun. Worked fine.

DAP - Rapidfuse

I'm a Super 77 guy myself:
https://www.3m.com/3M/en_US/company-us/ ... 460&rt=rud

Also, I really like Kaizen Foam as replacement foam:
https://www.fastcap.com/product/kaizen-foam
They stock it at Woodcraft in Seattle.

As the others have stated contact cement.

I decided to use hot melt glue as that seemed the most recoverable from if I screwed it up. Knowing what I know now, I wish I'd have made the slots for the magazines more central as the case is definitely tail heavy with six loaded magazines in there.

Here are the results:

I’ve heard of spraying the foam with plasti dip to hold it together


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What foam did you use? I might replace the pick and pluck crap on my pelican


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I can attest to plastidip working well. I really hosed mine down with something like 6 coats. It holds up well to lubricants too. Keeps the foam from wicking all the oil away.

Warning: I keep a pair of dessicants in the case as well. With that rubbery surface, I worry about condensation. It is a superior grip and protection though.

At far as foam...I used the cheap camping mats. It's 1/2" tight celled foam. You just cut it in layers and glue together to form a block. I made multiple layer blocks this way, and it's super easy to cut when it's thin. It also allows for multiple layers of different composition. Think of it like trays for components.

Cut the blocks to internal case dimensions. Once you coat with plastidip, it's a snug fit for the case.

For an easy foam source, check into Fred Myers. Almost every store has several different selections of foam mats. Gray 4"x24"x72" is like 10 bucks. (The pro's use a bread knife for custom cutting) Trust me, it works

I also don't put any gear in the lid foam, because sure as shit when you do...you'll find that bitch flipping over every time you open it.
Well, there is one exception. Lighting! I use $5 bump lights, with a channel cut in the foam.

After all...who knows where or when you'll need what's in the case. I'd rather not have to fumble with a flashlight to deploy.

Room for six more on the other side to balance the load!