Our beers are stored in plastic boxes, like everywhere, and these are very strong (some guys made a chapel with it!). Rather than using them as bricks I chose to transform them into a toolbox.
It's a funny project (of course) that resulted in a heavy-duty, cool and spacious toolbox. I'm sure I'm going to make some jealous people on the work sites ;-)
Al you need:
- two beerboxes (one for the box, one for the cover)
- some good friends to give a helping hand
- some plywood
- a piece of aluminium sheet
- some scrap metal for the handle
- (polyurethane) glue
- chemical anchor
- a pair of hinges
- some bolts
Step 1: Prepare the Box
Any beerbox will do the job. I chose Westmalle Tripel, a strong blond beer and one of my favorites. This type of beerbox is relatively high and has the perfect dimensions for a toolbox-project.
Use saw, cutting pliers and knife to remove everything you don't need, and keep just the bottom of the box.
I decided to glue some plywood in the beerbox. This gives a perfect bottom and a perfect surface to attach the handle and the hinges. Use polyurethane glue.
In the hand-holes I glued plastified plywood as well, shaped with a jigsaw. In this zone the hole for the handle will be drilled.
Attach the frame-side of the hinges, and almost ready is your box.
Step 2: Prepare the Cover
Cut out the bottom of the second box, shape some plywood and go for the glue. Use thick plywood inside, tiny plywood outside, with a small piece of plywood on the underpart of the cover as support for the hinges. Drill the holes for the hinges.
Cut out some aluminium sheet for the cover with a jigsaw. Use this sheet as model to set out the zone you'll rip out. Use a ripper to smooth the edges and to rip out some wood from the top. Paint the edges and glue the sheet in the cover.
Step 3: Prepare the Handle
Cut everything into the right size, and look out for some big wood bolts.
Drill holes in the sides of the handle and use a hammer to smash the quartered end of the bolts into the aluminium.
I didn't want to spend lots of time, so I filled the steel tube with chemical anchor and put the two prepared pieces into place.
Ten minutes later: some sanding and the only thing I had to do was to drill some holes in the downside of the handle to attach it to the box.
Final phase: paint it.
Step 4: Assembly!
Ready is your toolbox! Enjoy!