Fitted boxes

[Woody]

How would I go about creating a recessed, felt covered insert for a gun case? Any thoughts appreciated!
Woody

[Paul]

Try using polystirine blocks. You can cut out complex shapes using a "Hot wire" resistance wire attached to a low voltage power supply which melts its way through the block. Once you have the shape you want you can then cover it with felt, or if you want a harder finish you could coat the block with an epoxy.

[MadMark]

Insulation expansion foam. Put a piece of Saran-Wrap over the top and spray the foam under. Let it start to harden and press the gun down. The Saran-Wrap will deform to mate and the foam will harden in that shape. Once hard cut off the excess and use flocking (available from Rockler) to make a lined interior. Haven't actually tried this so you might want to experiment first with some scrap materials.

M