Here's a couple of DIY Custom Form Molded Cases from Vimeo member Roberto Caverra and Bernie Hipos. A couple of peeps with some DIY inspiration on camera bags and rolling cases.
Email from Roberto Below -
Hey, simple idea using expanding foam in a can. $20 case bought at a flee market, $10 foam can.
1. I covered all my equip very well with something like Cine foil and spaced them out to my liking.
2. Sprayed the expanding foam around cam body and lenses.
3. Once it was dry (about 24hrs) I removed equip and sprayed foam black.
Lenses and Cam body fit very snug and there is no movement once lid is closed. The cool thing is that you can cut it easily once dry.
In hindsight, I could have used more foam. I wasn't sure how much it was going to expand.
It's definitely a custom form mold to tightly hold the gear. I'm thinking another thin layer of black foam over the top and nobody would ever know what lies beneath.
For a Roller bag, Bernie Hipos writes in with a tip on using Foam Fabric from your local Fabric store (below). You can find the full WordPress post at his blog here: https://berniehipos.com/2010/10/17/diy-thinktank-bag/img_4402/. Cut out the forms for your gear and double layer it up to sandwich. Keeps things from shifting around during travel, as well as a bit of cushion to absorb shock impacts.