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Murphy's_Law
True, it could be a couple of inches taller. Can always compress it with a bungee strap. I'll definitely put a larger zipper slide cover - didn't extend it enough on this proto.
I've been thinking about foam but haven't found the right stuff and don't know what to search for. Something low density but stiff, 3-5mm would be ideal. Could maybe bodge it with some pieces of coroplast between the outer and liner but foam would be way nicer and easier to install.