I have some of the cheaper brands of metal and plastic cases. However it would be real nice to get the form fitted foam I see in some of the more expensive brands. At the same time I never see links or availability to just purchase the foam (figure they want you to get the case as well). Does anyone know of any dealers that would have this and/or a way this can be done with a large piece of foam. I tried once with a razor, needless to say "I ain't no surgeon" cause it looked like $%*@. Thanks

I think sometimes sheets of the foam can cost up to $30.  I've got a starlight that I cut myself.  The easiest way I've found to do it is to trace your weapon onto a piece of cardboard, cut it out, then trace it onto the foam, then cut (slowly and carefully).  

I take it you missed out on the ($43) Sams Club starlight cases eh?

Damn, yes I am sure I did. How long ago was that? I could go check and see if they have any on clearance laying around.