I only use the foam cutouts that come with the hard case. I have one hard case and bought a box of 4 foam additional inserts that are all custom cut for each rifle I may take. So that is 5 foam cutouts for one hard case. I want things as protected and tight fitting as possible. The ONE reason I do this instead of not using the foam cutouts is because of one experience I had flying back from Cordova AK. TSA took my hard case, opened it in front of me, pulled every single item out of the foam and then pulled the foam out also. I about lost my mind. Once she was done, she started shoving my stuff back in very carelessly. Granted each item had a cutout for I o go back into but her carelessness was not welcomed. I immediately spoke up and said, “mam, I am more than happy to repack that case for you here in front of you to insure things are to my satisfaction.” She turned to me and with a typical bitch face said, “you are not allowed to posses or touch this case or any belongings in it from now until you reach your next destination.” I then said exactly what was on my mind to her.
My freinds case was next, which was packed with the foam out and clothes etc repacked around the gun. She basically did a fire sale on it and threw all of his crap back in and closed it up. No where even remotely as tight or neatly packed as it was originally. I have only seen that happen once in all of my years, but it’s reason enough for me I won’t travel without the foam.