With the X jaket,actually the only dimension that is different is the length, and that is only about 1/2 inch. I still have enough room to put a thin layer (1/8") of dense foam to protect the camera a little better. I had to put a small block of wood in as a spacer so that I could anchor the camera to the box via the tripod screw. When I first got my box, I very seriously considered sending it back for a smaller (more expensive) one, but realized that the others really werent much smaller, and in some cases although they were shorter, they actually stuck out farther from the helmet because of design issues. As for making a smaller box, I am not sure why they dont re-tool and make a second one. Maybe they are too lazy? I'll just put it up on the classifieds and see who bites :)