For about $40 you can get a 40ct case similar to your pelican, though much lower quality, off the auction sites. Probably going to be the most cost effective method of having a hardpack case with numerous cigar storage capacity. I have two of em, and I'm pretty certain I didn't pay over 40 for either.
Edit: I paid $28 and $31 for each of my 40 ct travel cases. They work fine, they seal well, hold a good amount of cigars, but I keep two fullsize Bovedas when I use em. Probably fit 32ish with the two packs?
Wonder if the foam trays are sold separately? I've seen the ones posted above that have the cigars surrounded, but the regular herfador foam trays that are just grooves allow for much higher capacity.
Dunno how big your case it, but then you can use your case for a hybrid humidor like mine: