Repurpose Plastic/Molded Tool Cases

I decided to see if I could make use of some old plastic cordless drill cases I haven't been using. While these things seem to collect a lot of dust, it turns out they are not good substitutes for a good quality shop 'dust collector'.

Find out how to make use of these tool boxes, tips in modifying them, what mistakes to avoid, and how to fix mistakes (...at least those I made). If you melt plastic, always work in a well ventilated area and have a fan blowing any fumes (the fumes are toxic).

This video is intended for entertainment purposes. Always use caution and appropriate safety equipment. If you do anything discussed or seen in this video you do so at your own risk.

Music: Rockabilly Rumble. It was not attributable to any particular artist and was simply included in Adobe Premiere Elements 13 (yep, I'm still using version 13)

[foxcanfarms]

I thought it might be helpful to pin a comment regarding the wide tipped soldering gun/iron:
- We didn't make it (although one of my kids has an idea for making one 😀)
- The manual calls it a "Flat Iron Tip"
- The only places I can seem to find the Flat Iron Tip is in the "vintage" soldering gun kits
- - Examples include the WEN 199K, 250, and the 450 (I have these); and the Craftsman #5380 (I can't speak for this one).
- You can find some of the tips for the above models on eBay, but otherwise I haven't seen any new soldering kits with this attachment
- If you want one, you may have to go to eBay, garage sales, or estate sales

How these are supposed to be used: Technically made for smoothing and removing dents from wood (must use with a damp cloth), removing scratches from wood (use a wax filler), and for sealing wax paper packages and plastic bags! I imagine that in our throw away culture the need for this has significantly decreased (and there are now much better tools for those who still do this on fine or antique furniture).

Regarding Vintage Soldering gun kits:
- I like both vintage and 'modern' tools, but I haven't had good luck with 'new' soldering gun kits. They took too long to heat up and just didn't work well (maybe I was too cheap and didn't spend enough money).
- I bought a "vintage" soldering gun for less than a new/modern one at an estate sale I was hooked! So much so that I decided some time ago I might make sure that each of my kids has a good "vintage" soldering gun.
- I have accumulated quite a few of these vintage kits. Maybe someday I'll make a video about that and which of the vintage ones I don't care for (btw the ones I mentioned above work well)!

The other tip I use for plastic is called a plastic cutting or smoothing tip (mine is currently broke). It's easier to blend/push the new plastic into the old with these, but the "Flat Iron Tip" wide tip works better for smoothing and getting a nicer finish (even though it wasn't technically meant for that type of work).

I hope that helps, and I really appreciate all the comments, ideas, etc. !!

[ShanLiB]

If you live in an area like Seattle (or Portland, or Chicago, etc.) these are great, with foam inserts, for carrying your pistols to the range. It keeps your "Karen" neighbors from calling 911 to report you for doing something that is lawful. Works great.

[lesizbollzacke]

I have seen literally hundreds of these blow moulded cases thrown away over the years - it's great to see them re-used.
What I dont understand is most power tools COULD be sold in EURO containers with removable inserts. So once the tool was kaputt you could still utilise the case. They stack great too.

[corey]

I have done this to a few blow mold cases over the years. Sometimes it works to leave part of the mold in place. I have a small Rigid router that I left the part of the mold in place that actually holds the router and wrenches, but I removed a large area so that I didn't have to coil the cord so tightly to fit the case. Now everything fits better and stays secure.

[dpnerill]

Just today I saw a great idea for plastic repair like you were doing. What they used was a piece of metal screen melted into the repair area (a little larger than the area to be repaired) to act like tiny rebar. After melting the screen into the plastic, another piece of plastic, cut from a piece you are throwing away (or from a hidden spot) is then melted on top of the screen making it a strong seal.

[paddrivers]

I like it.
I've seen these thrown in the dumpster from time to time... and now I'll grab them !

[gromeca]

Great video. My tools are so old the cases are metal. The good’ol days

[thedevilinthecircuit]

You can use a small 40-watt soldering stick and zip ties like a TIG welder to repair hard plastics. One of the issues with thermoplastics is they don't respond well to excessive heat (they break down), so use just enough heat to get the plastic to flow without discoloring it. If it starts to turn black, it's getting burnt and that makes it extremely brittle.

[fantasticsound]

I've been doing this for about 25 years. I began with a medical device case I purchased for $5 at an estate sale. It's held an EV RE20 mic for over 20 years. I custom cut open cell foam to fit. Same for a Nikon SLR I've had for 15 years. It was a repurposed, DeWalt quarter sheet sander case. The foam has spaces for the camera with lens, another lens of identical size, the battery charger, a monopod adapter base and several other accessories. My favorite case is an old Black & Decker cordless drill case that has a bit/fastener storage on the outside. I have used that case for tools for years, but 20 years ago it accompanied me in a PA road rack, half way across the world for an Armed Forces Entertainment tour to the Middle East. I ended up with a slew of free cases when the scene shop o worked decided to get rid of the original cases for most is their tools as the tools either lived in the shop or in larger, workboxes for site builds.

When you need a water resistant case for a particular item that has none, many of these often free cases will fit the bill with just a little modification.

Great video. Like I said, I've been doing this for over two decades, but it is certainly something that many people have never thought of but could find extremely useful and cost-effective for a wide variety of storage needs.

Your Makita case was a lot simpler than most. All the DeWalt and other cases with similar blow molded inserts I've altered were plastic welded to the outer shell. Yours just popped out of one side.

[louiechidwick]

Hi mate, greetings from the UK, I've done something similar to this with slim cases that housed socket sets, screwdrivers, drill bits, etc.
I cut the inserts out and placed them in the draws of my metal tool cabinet, then I put the tools back in their original places, all stored neatly away and ready for use.

[bradfaubion]

I love this, thank you. I hate throwing these useful cases away, now I can too reuse them!

[thomaslthomas]

I’ve done this for several things.
My day job is a professional musician.
I find these work well as a pedalboard fly rig.

[kellylinder]

I used a Dremel tool with a plastic cutting disk. The edges were smooth and there was less chance of cutting through the case. It was probably slower though. I put two carriage bolts through each side of the case. I keep my table saw dado set in it. I use a wing nut on each bolt to hold them in place.

[rickbumeter]

I too used a large multi tool case for all my trailer straps and it works fantastic. Just recently grabbed a Dewalt case and stored a log chain in it for easy tote and storage. What a difference carrying a case with a large chain inside versus by itself. Just thought I would share. Thanks for the ideas.

[BrassLock]

Your demonstration of plastic remodelling/repair welding using a soldering iron with an iron-shaped foot was really interesting, thanks 😊

[Bootstrahps]

Hell yeah man, I am embarrassed at the amount of Milwaukee hard cases I have in my basement. A decent alternative to packing them full with stuff is getting some of the thick black foam and digging out the foam to form fit certain tools! I did that for my impact socket set. Thanks for the video! I hit the like and subscribe button

[swnorcraft]

Cut around the bonded spot with a small hole saw. Then smooth what's left with the flat iron. I have repurposed a few of these myself. Where I work, the community tools get the most abuse. I have taken hole saw kit boxes and removed the innards. As they are smaller than the suitcase type, they can be used to make a smaller kit. Good stuff! Thanks for sharing. Use the small bit tray for a drill press accessory pocket. Figure a way to fasten it on or near your drill

[shaneridge]

That's genius I have a few of these that I want to modify now. Combine this case with a 3d printer and you could make some pretty awesome tool holders

[RG-cehj]

I have a 12 volt compressor and tire repair stuff that just bounces around behind the seat of the is a great solution to keeping it all together! Thanks for the video! 👍

[richcxx]

Great idea, now I am depressed over all the cases I have tossed over the years!