You may have seen parts bin shelves for sale (Harbor Freight Tools recently listed some for about $100). I came up with a way to make your own from squarish empty bottles (caps optional), 1 or more cardboard cartons that hold the bottles without large gaps (i.e., the carton the bottles came in), and possibly a piece of corrugated cardboard or similar material. Round or curved-side bottles won't work. The only tool needed is good scissors. A hole punch, polyurethane or paint, paintbrush, & tape are optional.
To clarify: A carton is described as it will be placed so that front refers to the open end that was originally the top, back refers to what was the bottom, and bottom & top refer to what were sides.
Top of bottle side refers to the point where the side of the bottle turns inward to meet the bottle opening.
Internal refers (if using more than 1 carton) to a carton top, side, or bottom that abuts another carton (not the surface the carton rests on).
External refers (if using more than 1 carton) to a carton top, side, or bottom that doesn't abut another carton (but can rest on the surface).
To convert a bottle into a parts bin:
1. Cut a hole in the side of the bottle that will become the top of the bin; for maximum strength if the bin will be used for heavy parts limit the hole to the flat part of the top (I strongly recommend using scissors since I found it hopelessly easy to cut too far using a knife).
2. Optional - Use a hole punch to make holes where the corners of the top opening will be.
3. Trim the hole to its final size.
4. Optional - Put the cap on the bottle (besides stopping the contents from falling out it makes a good handle).
There are a couple ways to use cartons to hold the bottles; I will first describe using a single carton, then using small cartons in a modular form.
1. Fold the flaps back against the inside of the carton.
2. Put the carton in the desired position and verify that it fits satisfactorily.
3. Put the bottles in the carton.
4. If the bottles are too tight at the sides fold one or both side flaps back against the outside of the carton.
5. If the bottles are too tight at the top & bottom fold the bottom flap & if also needed the top flap back against the outside of the carton.
6. If the bottom flap wasn't folded back in step 6 cut a piece of corrugated cardboard or similar material as wide as the bottom of the carton and slightly longer than the distance from the front of the carton to the bottle side top (make sure the bottle is pushed all the way back in the carton).
7. If the bottom flap was folded back against the outside of the carton in step 6 and extends much further back in the carton than the bottle side top trim it so it only extends slightly further.
8. Optional - If the flaps inside the carton extend further back than the bottle side top trim them so they don't quite reach the bottle side top (this makes the bottles looser but less likely to fall out).
9. Optional - For added strength, unfold the flaps, polyurethane (don't waste outdoor (spar) polyurethane for this) or paint the inside of the carton including flaps (ideally, do this on a warm day and put the carton in front of an exhaust fan; it will dry much faster and smell up the house much less), wait for it to dry, and fold the flaps back as they were.
10. Optional - Unfold only the outside flaps, polyurethane or paint the outside of the carton including all flaps and the piece of cardboard, refold any outside flaps, and let dry.
11. If the bottom flap wasn't folded back against the outside in step 6 tape the piece of cardboard to the front of the carton bottom (this is an anti-Murphy's Law measure that gives the carton a slight inward slope so the bottles will tend to slide back in rather than fall out).
12. Optional - Tape the flaps in place.
13. Put the bottles in the carton and use; note that it may be necessary to hold the above & below bottles in place when pulling a bottle out.
If using more than 1 carton:
1. Decide how to arrange the cartons; while long side horizontal should be more convenient, if stacking cartons that will contain heavy parts it is better to have them vertical for greater strength to reduce sagging problems.
2. Choose the squarest and best condition cartons for the bottom row.
3. Follow the same procedure for a single carton with some complications:
At step 4, fold back an external flap first; unfold but don't fold back an internal flap.
At step 5, fold back an external flap first; unfold but don't fold back an internal flap, top flap first.
At step 6, if some but not all bottom flaps are folded back against the bottom, get annoyed and do one of the following:
A. At step 6 only cut cardboard for the cartons that don't have the bottom flap folded back on the outside.
B. If applicable, fold the outside bottom flaps back inside the cartons and fold the top flaps of those cartons back against the outside or if internal just unfold them.
C. If applicable, fold the inside bottom flaps back against the outside of the bottom and fold the top flaps of those cartons back against the inside.
D. If there is more than 1 row of cartons, swap cartons from the bottom row with upper rows to get all the external bottom flaps folded the same way.
E. Fold the outside bottom flaps back inside the cartons & live with the bottles being tight.
F. Fold the inside bottom flaps back against the outside & live with the bottles being loose.
Optional - Before steps 9 or 10, if an internal flap is unfolded while the flap of the abutting carton is folded cut off the FOLDED flap & when dry fold the unfolded flap back against the inside of the abutting carton to hold the cartons together; if both flaps are unfolded cut one or both off.
Optional - At step 12 also tape the cartons together, either a row or column at a time or as a single unit.