So here again. In this I'ble I'm going to show you how you can easily make a custom heavy duty toolbox from a plastic beerbox.
A few years ago I already made such a thing, using two beerboxes. It's still in use, of course, since it's very sturdy. It's made by me. Jokin'!
It's just a bit, well, too sturdy (read: heavy) and so I decided to make another one with (another) one of my favorite beer brands. The advatage of Jupiler TAURO - a deadly accurate strong blond beer - is that those boxes got a handy handle in the middle - a feature that opens a lot of possibilities...
Yes, in Belgium our beerboxes are still made from plastic and they are veeery tough - there are even guys who make whole houses with it! So using them for a toolbox is a logic idea. They are also quite spacy so you can store a lot of gear in it.
And they are lightweight.
AND they form a useful step on every worksite.
I'm a fan of beerboxes, totally.
Step 1: Closing the bottom
Measure the size of the gaps and go mass production.
Copy the measurements on a piece of plywood and use a clock drill to drill the holes for the bottle spacers.
Don't throw the wooden discs away, you'll use them later.
Use a mitter saw to cut the 'puzzle' pieces.
Smash them in the bottom of the box. No screw no glue, just good old pressure.
Step 2: A little bit of demolition
I modified my PMF aka multitasker in a 90° cutter and it worked just perfect to cut those plastic trees down.
A bit of sanding and you'll have a perfect bottom.