The more I check out Custom Foam Case Inserts - MyCaseBuilder.com the more I think I will try them out. I've found the cases other places cheaper without foam. Then have these guys custom cut it seems like a decent deal. I'm still not sure what road I'm going to take, but there are some interesting options out there.
Here is a good thread on the subject. Cutting Gun Case Foam (lots of photos) - AR15.COM
That custom foam site is pretty sweet I got two old Pelican cases I want to turn into gun cases but that have no foam in them