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Range Officers
May 2, 2009
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I've used the expanding foam method before, but usually for building shipping boxes. It is cool to make a perfect form of an object. Also, it does create serious pressure--I blew a few boxes apart in the learning process.
If you have a spare can of expanding foam around, and want to play....
take a gun and stick it in a small trash bag and suck out as much air as you can... tape the end shut flat if possible (like a zip loc)...
line a cardboard box with a big trash bag--
Shoot some foam into the cardboard box, quickly lay the bag/gun as flat as possible of expanding foam, shoot more foam over top of gun, close big trash bag, and close box....hope foam doesn't blow sides out of box 
once it hardens, you can slice it in half and have perfect top/bottom of gun. Takes practice.
SHOOT
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Dans Club
December 4, 2011
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Spray can foam doesn't expand all that much but the two part foams, will expand something like 50 times their initial volume, VERY quickly. These are high density foams so a lower density may not expand as much but still expand rapidly.
Anything worth doing is worth doing well.
My father
If a man designed it, and a man built it, then a man can fix it.
My grandfather
January 15, 2010
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I must admit I have never seen an original DW Pistol Pak in person, nor pictures of one without guns in it. Can anyone answer these points?
* Did they use a firm molded foam or spongy open cell foam?
* Is the foam underneath fitted / molded /plucked to fit or just flat?
* Is the fabric glued or just pulled tight on the foam?
I have done two molded velvet pistol cases like the one pictured, (never tried to replicate a DW pistol pak). The other was for a smith model 41 (a $900 gun). I practiced with one part foam on a crossman air pistol. Once I had a method established, I had no fears of damaging that blued - wood gripped model 41 sweetie. When all the wrinkles and corners come out looking just right, its really worth it.
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December 4, 2011
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The origional Monson packs I have both have open cell foam cut to fit the outline of the guns they hold. One is a VH pack and the other is for standard underlug. The fabric in mine are both just laid over the foam and tucked underneath. I used pins to hold mine to the foam so it wouldn't crawl up and wrinkle eveytime you too a piece out of the pack. The one pack I bought (black case) came with no cloth and I believe it never had cloth from the factory. I put cloth in it since the gray foam looked very drab with a pristene 22 set in it. I think the factory used hot wire cutting to shape the foam. I used a good pair of scissors and a razor knife to cut the foam in the scratch built pack I did for my one 15-2.
Anything worth doing is worth doing well.
My father
If a man designed it, and a man built it, then a man can fix it.
My grandfather
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January 24, 2009
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Marvin, I've only got this one shot of an empty factory case. Someone cut in their own extra grip spot, otherwise it's as it should be.
The bottom foam is two pieces. The lower piece is just flat, the upper piece is roughly 1" thick & is cut out. With the cases that use fabric, the top foam is flipped over so the smooth side faces out, then the fabric is just tucked in, as Scorpio stated.
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