#3. "RE: need help with camera protective case with d700" In response to Reply # 2
The Pelican case instructions suggest using tooth picks to lay out the extremities of the equipment and then remove the foam afterwards.
Personally I'm pretty adept at putting the camera/lens on top of the foam and then determining the dimensions conservatively and plucking out the foam core. You should have a very snug fit at this point or slightly undersized hole. I'll then trim out the final foam to accommodate the equipment comfortably.