Hello Philip;
Yes I did it myself, I bought a set of military grade high density foam (
https://www.ebay.com/itm/3pc-Benchm...616490?hash=item36556fae6a:g:jNEAAOSwuZBdmeAo) to cut several patterns depending on what I want to bring along. I traced the outlines with a marker and cut carefully with a sharp kitchen knife using a metal ruler as a guide in the long cuts. The main challenge is to hold the knife truly vertical so that the cuts are not slanted sideways.
Your concern with the regular Pelican Protector cases used as suitcases is exactly the reason why I did NOT choose the Protector 1650. As discussed at the time when
BeeMaa was using two of them, to me it fails both critical criteria of size and weight:
--- With exterior Dimensions: 31.59 x 20.47 x 12.45 its total linear dimension is 64.51". This exceeds the 62" maximum allowed by airlines.
--- Its weight empty is 24 lbs. This is half of the maximum 50 lbs. allowed.
I know that a number of folks are willing to take both the oversize and overweight gamble, but in my personal view it is just a matter of time before airlines realize the loss revenue opportunity when they do not enforce 62" and 50 lbs. I am not taking this bet... With 3 flights out and 3 flights back, the potential ~$100 fee for each flight would cost me $600. I can think of better ways to spend these...
I use an Air 1605 when going for a short hunt in a single climate, but it is a little too small for a 3 week Eastern Cape hunt where I need to bring both a hot plains outfit and a cold mountains outfit. Additionally, when loaded to 50 lbs. capacity the absence of wheels on the 1605 is really inconvenient to schlep its through airports...
I love the Air 1615 for five reasons:
- With exterior dimensions 32.58 x 18.40 x 11.02 its total linear dimension is 62". This meets the maximum size requirement.
- It is large enough to accept bulky items (e.g. midweight boots and insulated parka for Vaal Rhebok hunting in Eastern Cape mountains in winter (July to September) where you can expect white frost in the morning and evening, and 40F to 50F during the day.
- It has wheels.
- It is light. Actually, it is tall enough that you can roll it using the side handle, so I unscrewed the extendable handle and I also removed the side handle on the wheels side to minimize weight. It comes down to 12 lbs. 12 oz. empty. This allows me to take 37 lbs. With the ~11 lbs. of ammo, I can still take 26 lbs. of gear, which is plenty.
- Some say the Air series is not as strong as the Protector series. This may be true in the absolute, but it is certainly strong enough, in my opinion, for suitcase purposes.
One advice if I may: do not buy a black 1615. Chances are it will be confused by airline and TSA attendants for a rifle case. It happened to me with the black 1605 and caused endless gyrations around the theme: Her: "I am sorry Sir, I cannot check a rifle case, it has to go through TSA;" Me: "This is not a rifle case, this is my suitcase;" Her: "I cannot check a rifle case, it has to go through TSA"......... You can get an orange, silver or yellow 1615, or even indigo blue or oxblood dark red if you take the Packing Cube Organizers option, but it costs $100 more. I took silver...
I use a Pelican 1150 for ammo. I looked hard at the 1200 many people use, but I do not need mine to be this big because I see no point in taking the bulk and weight of ammo factory boxes, and the 1150 is 1 lbs. lighter than the 1200. In a game where every pound counts, this is very significant to me.
Besides, using ammo dividers from older Weatherby factory boxes, I can put up to 150 combined rounds of .257 Wby .300 Wby .375 H&H in the Pelican 1150. More than enough...
And anyway, in about any combination I can think of, I reach the 11 lbs. maximum weight before I reach the maximum space in the 1150. For example:
--- 40 x .257 100 gr + 40 x .300 165 gr + 35 x .375 300 gr weigh 10 lbs. 13 oz. including box and TSA locks.
--- 50 x .257 100 gr + 40 x .300 165 gr + 20 x .470 500 gr weigh 10lbs. 14 oz. including box and TSA locks.
View attachment 375187
View attachment 375188
I put the 1150 ammo box inside the 1615 suitcase for international flights, and I take it out for South African Airline internal flights where ammo has to travel separately.