Peli Air 1606 Replacement Foam Set

Restore or Upgrade the Interior of Your Peli Air 1606 — on Your Terms

The Peli Air 1606 Replacement Foam Set gives you complete control over the interior of your case. Whether you are replacing worn or damaged foam after years of use, reconfiguring for a different equipment layout, or setting up a custom fit from scratch, this set delivers the same pick-and-pluck foam found in factory-configured Peli cases — sized precisely for the 1606 interior cavity with no trimming required.

Pick-and-Pluck Foam: Precision Fit Without Any Tools

The foam layers arrive pre-scored into a uniform grid of small cubes. Customisation requires no cutting tools, no templates, and no specialist equipment. The process is entirely hands-on:

• Arrange your gear on the foam surface in the layout you want.
• Mark each item's outline using masking tape, chalk, or a fine-tip marker.
• Remove cube sections by hand along the pre-scored grid lines.
• Lower your gear into the shaped recesses and verify the fit before finalising.

The cube grid allows precise adjustments in small increments, so cavities can be sized accurately without overcutting. Sections removed from an upper layer can expose a deeper cavity — useful for items of varying height that need to sit at different depths.

One critical measurement to maintain: keep at least one inch (25 mm) of foam between your gear and the outer walls of the case at every point. This buffer absorbs lateral impacts and keeps each item from making contact with the shell during transport or if the case is dropped.

A Direct Fit for the Peli Air 1606

This foam set is dimensioned specifically for the interior of the Peli Air 1606 case. The foam drops into place without modification and fills the base cavity fully. The foam colour is black, consistent with standard Peli interior configuration.

When a Replacement Set Makes Sense

Pick-and-pluck foam is durable, but it degrades over time — particularly along cut edges and in areas subject to repeated loading and unloading. A replacement set is appropriate when:

• Existing foam shows visible compression, crumbling, or deformation along cube edges.
• Your equipment configuration has changed and the current layout no longer fits cleanly.
• A case is being repurposed for a different role with different gear dimensions.
• The original foam was removed and the case needs to be re-equipped for active use.

Quick Specs

• Compatible with: Peli Air 1606 case
• Foam type: Pick-and-pluck (pre-scored cube grid)
• Colour: Black
• SKU: 016060-4000-000E
• Customisation: No tools required
• Minimum wall clearance recommended: 25 mm (1 inch)

Who It's For

Field service engineers, photographers, broadcast crews, electronics technicians, and security professionals who use the Peli Air 1606 for transport. If your foam no longer matches your gear layout — or if wear has reduced its protective capacity — this replacement set restores the case to full working spec. The same result as a factory-configured interior, built around whatever you carry.