In the last two weeks I renewed the setup of all my remaining pelican cases completely. The last few years I didn´t buy the original pelican foam anymore since it is way too wobbly for me and doesn´t hold the lights secure once the case is open. I always use closed cell foam now. The trick is to cut the inlay slightly larger than the case itself would hold so that it compresses a bit when inserted and the inlays for the lights slightly smaller than the lights themselfs. That way the foam holds the lights even when the case is open - you can hold it upside down and even shake it and they wont fall out!! You´ll have to leave the lights inside the case for a few days and after that the foam adjusted itself to the form of the lights and will hold that form even when the lights are not inside the case. Eventually it will return to the way it was cut but that takes quite a while. Also I try to cut a bit longer than the light itself so that the foam does not touch the lens. I also decided to represent what´s inside the case with a sticker on the Pelican label.
Pelican 1200 with my remaining customs:
Pelican 1170 with my Pocket Rockes:
Pelican 1170 with my "tanatized" Surefire E-Series:
Pelican 1400 with some of my Surefires:
See how the foam clings to the lights..... and in the next picture how the foam resembles the form of the lights:
