Building a cooler

[Treeview]

I've got an 80 qt. Gott/Rubbermaid cooler like this:

http://orlando.ebayclassifieds.com/sporting-goods/maitland/gott-80-qt-cooler/?ad=27347210

I'm less than impressed with it's insulation. Besides, the handles stick out and take up more space.

My idea is to cut out the bottom tub of the cooler then mate 2" blue foam [at least] to the outside. Maybe another layer in the bottom too.

The inner lid will likely come along too. The new outside shell would likely be made from FRP.

does anyone know what the R Value is for the insulation in the original Gott cooler?

Someone else must have built their own cooler to fit a custom space. There are some ideas for doing just that inside my head already.

Thanks,

Tom

[Mary C]

Tom there have been several "homemade" coolers. they have been discussed in various ways on the Foamie big thread and I believe Slow has a cooler made with foam. don't know anyone else by name, that has one but I have been thinking about building one myself. I know the Thrifty thread is long but it is there on it somewhere. I was thinking about making one using 2 inch foam then using material. canvas and then poly and more poly. I was going to do the same on the outside. I can make shelves and ways to separate foods from the melted ice. Good luck!!

Mary C.

[Treeview]

Ahhh...thanks for helping me focus my search. I'll find those builds.

Tom

[Festus]

I have thought about making my own cooler as well, but have not decided on my approach to the project yet. My main decision was due to the fact I can't justify the cash for a Yeti, Yukon or Canyon cooler. I can buy a lot of ice for what those models cost.

I am a little surprised that one of the cheaper cooler manufacturers haven't come out with a higher performance cooler (with a higher price tag) to expand their market a little more. They could use an existing mold of either the inside or outside (choose one) and add more insulation, a few bells and whistles and they could produce a nice cooler for probably 50 or 60 bucks retail. I think that quite a few people would buy one at that price point, as opposed to hundreds of dollars for the high end coolers.

And if any cooler manufacturers are lurking out there, here is my wish list.

1. Insulation- it's what makes a good cooler and it's not that expensive, so don't skrimp here. 1 1/2 to 2" on the sides and bottom, 2 - 3" for the top.
2. Feet on the bottom- at least 1/2" high to keep the bottom from sitting directly on hot ground.
3. Weatherstrip around the lid.
4. Decent handles, hinges and latch.
5. A price that is affordable enough for the average Joe to buy one. This is where a I have a problem with the premium coolers, but maybe that's just me. After all, a Ford and a Ferrari are both transportation, but the Ferrari is a premium, high performance, low production automobile. (If my ship ever comes in, I can carry my Yeti in my Ferrari)

In the meantime, I'm back to thinking about making my own. I'm thinking pretty much along the lines you are, except I'm considering bending up a sheet metal exterior. I've also considered using Reflectix insulation (it looks like shiny bubble wrap) and alternating layers of it and styrofoam. I don't know if it would work any better than plain styrofoam by itself. Some testing both ways may shed some light on what would work best.

[marshall0000]

I built my own ice chest because I wanted to use the cooler to support the ac unit I mounted on the front of my build with access doors on either side of the top of the cooler. I built a frame with small (1/2") angle iron then used plywood to fill in the frame. I then used 3 inches of rigid insulation on all sides and fiberglassed the inside using pvc pipe to make a drain. I have only used it once so far (just finished the build) but it was over 90 degrees and it seems to keep ice better than any commercial ice chest I have used. If I ever figure out how to reduce my pics to an acceptable size I will post them. If you are interested at all I would be glad to email you some pics.

[PKCSPT]

This may be a dumb question but on the cheaper coolers, are the sides hollow? I don't want to cut into my new although cheap cooler to find out. If it is could a person drill a few holes and fill with spray foam?
I am thinking of just lining the inside with some thin Styrofoam. I only go for a day or two but think about it.

[Shadow Catcher]

The sides are not hollow. One way to improve insulation is by adding it using insulation. I used the bubble reflective insulation for its reflective value to the outside of our Waeco refrigerator. In tests using heat two layers gave a 50% increase in insulation value but there is controversy http://www.greenbuildingadvisor.com/blo ... -good-idea
My reason was that the casing on the refrigerator is dark gray this adds a reflective value.

[PKCSPT]

Well now I know. Interesting article.

[Jim.M]

The sides are not hollow. One way to improve insulation is by adding it using insulation. I used the bubble reflective insulation for its reflective value to the outside of our Waeco refrigerator. In tests using heat two layers gave a 50% increase in insulation value but there is controversy http://www.greenbuildingadvisor.com/blo ... -good-idea
My reason was that the casing on the refrigerator is dark gray this adds a reflective value.

If your waeco is anything like my dometic, I get the most 'bang for the buck' by putting inches if insulation under the unit. Lift your waeco after it's been on that wood floor for a few hours, and notice that the wood floor under the cooler is now the same temp as the stuff inside it!

Those cooling panels are in the bottom and they didn't do a good job (efficiency-wise) insulating the floor of the cooler. The lid always seems like it needs more, but shooting it with an infrared thermometer indicates otherwise.

[Bogo]

I am a little surprised that one of the cheaper cooler manufacturers haven't come out with a higher performance cooler (with a higher price tag) to expand their market a little more.

Coleman 5 day Extreme coolers. I've seen a 70 quart one on sale as low as $38, but $50 is more typical for a sale price. List is $80.

I have one, and it works nicely.

[Shadow Catcher]

Jim, thanks for the tip I will now put it on a closed cell neoprene pad.