When we acquired our beautiful Oculus Rift DK2's, we were rather disappointed with the carry case. It's pretty looking and similar of a well constructed Apple product box, but it isn't particularly robust to be sent with a courier unless you packaged it again [insert Inception meme here]. Plus, if it rains while you're carrying it, the cardboard will eventually absorb enough water to damage its precious contents.
So we decided to find a solution. We went ahead and created our own foam inserts which you can now download for free [below] and manipulate for your desired flight case. Most flight cases ship with pick and pull foam, but due to the frequent use of people using the case it would soon deteriorate, which is why we went down the solid foam option.
Here's what we used if you would like to replicate the images below.
We would suggest lowering the DK2 by a few mm and purchasing a thinner egg foam insert for the lid as it may be a little tight. We hope this helps those of you out that may need it and if you mod it in any way take a picture and be sure to post it on our Facebook page.