I thought I would add this bit of detail to this. For just flying and stuff, my Winchester box did me well. It is a small 2 pistol case which I just flew with this week. When I bought it, the bottom foam was too thin to hold the guns well, even without cutting. I decided to replace with thicker foam and cut with a "turkey knife". I can tell you it worked great. I traced the shapes with tailors chalk, cut the foam out with the knife. Next time, I think I would do 3 things different:
1. Cut out a smaller profile of the guns. I went about .25" smaller all around the chalk line. I think I would change to about .375" smaller. The guns are tight, but not real tight like I would like.
2. I also would not cut clear to the edge of the foam. I did this where the ammo goes and that left the ammo a bit loose. Oh well, I can live with it.
3. I will also glue in the foam that I cut to depth with spray adhesive. I haven't done this yet, but I need to. This was a rush job.

Tips:
- Focus on the general shape and cut to the small side.
- Plan on adding the cut out foam back to get the proper thickness. i.e. cut the piece out with one smooth cut. No extra cuts for sharp corners.
- If you are cutting the original foam to fit the inside of the case, cut over size .25" on all sides to add some built in compression. If your foam is harder, this will be less.

Back to the Winchester case review, it has flown twice with no damage to the outside. These were both 1 transfer flights. Let's see, I guess it has been handled by the pros for 6 on/off cycles.

Also, if traveling matters to you, I'm going to start a travler's tips post. Look for it in Off Season.