Thank you for your reply and suggestions.
Right now, I am using the Pelican Case replacement foam inserts. It’s Polyurethane, open cell. I do have some other inserts coming made from some cross link Polyethylene. I want to give those a try to see in I have different results.
Yes, the cut at the top of the insert would be the most important part of the project, but there are cut outs that would need to get maybe 1/2 a thickness of foam placed back into the cutout so it wouldn’t need to be full depth. I planned on using the plug that came out, but with the bottom being so much larger than the top, it has too much slop.
I will try to run it at a lower power and a couple of passes, as well as ramping up the power too.
Thanks again for your help.