I have several empty molded plastic tool cases left over from tool transactions and garage sales hunting. The kind where the tools are held in recesses molded in the plastic. Unfortunately, those are pretty much useless if you don't have the exact tool that is meant to fit in the case. I tried selling a couple on CL with no success cuz the chance of somebody having the exact same tool without the case are rather slim. Which is also why I see those every so often given away for free on CL. The better ones are pretty sturdy with good latches and good hinges.
Well, I finally tried to see what I can make out of them. Turns out, unsurprisingly, that the cases are typically made of 2 layers of polyethylene. The outside one and an inner one that is molded to the tool. So I removed the inner layer to leave only the outer one. It's not quite as simple as it sounds cuz they can be welded together in spots. And you need to make sure you don't puncture the outer shell (too much). But I finally did it. Takes a while. Probably about an hour for me, even with the best tool I found for the job: an oscillating tool with an offset straight saw blade. Need to cut things straight, fight with the welds, negotiate all sorts of weird shapes and bends and then smooth out a bit the overly sharp edges... It's a bit of a job to do it right. Then add some foam.
Anyway turned out OK I think. You can then use it for a tool without a case or any number of other things. Yup, those other tools too...
(Although keep in mind that power tools are like candy for thieves...)
Here, to give you an idea of the final result. Note I could have made it a bit more even where it's cut but I wanted to keep a good chunk of folded lip for extra rigidity, yet not so much that the foam could not get under the lip.
Presto, got several more carry cases like this one:
Well, I finally tried to see what I can make out of them. Turns out, unsurprisingly, that the cases are typically made of 2 layers of polyethylene. The outside one and an inner one that is molded to the tool. So I removed the inner layer to leave only the outer one. It's not quite as simple as it sounds cuz they can be welded together in spots. And you need to make sure you don't puncture the outer shell (too much). But I finally did it. Takes a while. Probably about an hour for me, even with the best tool I found for the job: an oscillating tool with an offset straight saw blade. Need to cut things straight, fight with the welds, negotiate all sorts of weird shapes and bends and then smooth out a bit the overly sharp edges... It's a bit of a job to do it right. Then add some foam.
Anyway turned out OK I think. You can then use it for a tool without a case or any number of other things. Yup, those other tools too...
(Although keep in mind that power tools are like candy for thieves...)
Here, to give you an idea of the final result. Note I could have made it a bit more even where it's cut but I wanted to keep a good chunk of folded lip for extra rigidity, yet not so much that the foam could not get under the lip.
Presto, got several more carry cases like this one:
