Building a Fiberglass Cooler

[kempshark]

I was thinking of building a fiberglass cooler (of large size of 200 qt +), and had some questions. I was planning on keeping the cooler in my garage most of the time, and using it for beverages for large get-togethers and in case of power outages like during the last 2 hurricanes down here. <br /><br /> I figure using wood on any part of it would make it incredibly heavy. What would you guys suggest? Can I do it using just foamboard insulation (or something similiar) and fiberglass, and then gelcoat the whole thing? Or do I need to use some sort of composite for structural supports in some areas? <br /><br /> I'm a beginner when it comes to fiberglass and gelcoat work. But I figured it would be neat (and come in handy) to build a large, well insulated cooler like this. I could glass in a drain valve with a hose hook-up to make it easy to drain without lifting or moving it also.<br /><br /> Any hints, advice, or suggestions would be great.

 

[crab bait]

Re: Building a Fiberglass Cooler

i built one ,onetime as per a benchseat in my boat.. it's the best cottonpickin' cooler ever..!! keeps ice for 3 days in high heat..<br /><br />i'd use alittle wood..just for outside appearance an strenght.. you gotta have somethin' to latch the foam to..<br /><br />use 1/4 luan for the shell..it's strong a very lite weight..<br /><br />i use 2 in. owens pink foam.. glue to luan with 3M 77 spray adhesive.. works great an it's really 'the-right-tool-for-the-job'..<br /><br />the lid,, glue on a piece of pink 1/8 in foam first the full size of the lid.. then a piece of 2 in on that.. <br /><br />that 2 in. on the lid will be smaller in size by 2 inches all the way around.. as so to fit down inside the side wall 2 in. foam.. ( understand )..an the 1/8" foam the full size of lid acts as an 'imperfection seal'..<br /><br />the 2in. foam on lid ,,, you have to taper/camfer the bottom 1 inch somewhat as so for the lid to close as per 'lid/hinge' arch.. ( understand )..but keep the upper 1 in. of the 2 in. foam intact as per good tite seal..<br /><br />use piano hinge for the hinge.. <br /><br />also ,, DO THE BOTTOM OF THE COOLER LAST..!<br /><br />so you can get the foamed top lid an hinge right.. ( look thru the bottom of cooler to see what your doin' ).. if you do the bottom before the top ,, your blind..<br /><br />i fiberlassed the inside foam with epoxy.. pretty an neat is optional. but no sharp ragged edges should be..<br /><br />once it's good.. glue down a piece of luan in the bottom on top of the bottom foam.. bore a hole thru ( a standard brass transom drain tube size ).. glue in said tube ( cut lenght if need be ) install plug from inside the cooler side..

 

[ThomWV]

Re: Building a Fiberglass Cooler

Just a note. If you try to do this using polyester resin it will eat your foam in a heartbeat. Polyester will destroy all of your work faster than you can save it. You must use Epoxy.<br /><br />Thom

 

[kempshark]

Re: Building a Fiberglass Cooler

Did you gelcoat the cooler inside and out? Like I said, I'm totally new to the fiberglass work, so I wasn't sure what would be best for something like this. I was thinking that gelcoat would look the best. Would something else be better? <br /><br /> When you said wood for strength and appearance, what did you mean by appearance? I was thinking that a nice white or off-white gelcoat (or whatever) would make the best interior and exterior finish. What do you seal the whole you bore through the wood and foam for the drain with, epoxy?<br /><br /> I figured this would be a good project to build something useful and custom. Also, it would give me some practice and experience with fiberglass, epoxy and gelcoat for future boat related projects.

 

[kempshark]

Re: Building a Fiberglass Cooler

One other question, by Owens pink foam, I'm assuming you're talking about the normal soft, pillowy pink paperbacked foam insulation. I was thinking more along the lines of a rigid, waterproof foamboard insulation of some type. that's why I was wondering if I could build it just with the foamboards, fiberglass cloth, epoxy resin, and then gelcoat. I would think that it would be better to use a closed cell foam insulation when working with any potentially wet area. Hopefully, I would build it well enough so that no water would leak into the foamed area, but better safe than sorry.

 

[crab bait]

Re: Building a Fiberglass Cooler

the 'pink' foam i refer to is the hard construction board waterproof closed foam.. <br /><br />the 'pink,pillowy,soft,paperbacked foam'you refer,, is not foam but fiberglass an itchy..<br /><br />the wood ,, the 1/4 luan,like i said,, gives you something to build from an to latch/glue your foam to..<br /><br />you can still fiberglass an gelcoat the laun outside surface if you want .. the wood gives you ridigty, strenght, an a good surface to do a good job on... <br /><br />just foam alone,, fiberglassed,, stillwould ding,dent,crush, in short time unless it was 'boat hull' thick.. ( sense-less imho )<br /><br />i wouldn't worry about the inside.. to much hard work,, an almost impossiable to sand an finish right.. <br /><br />i'd try painting the inside foam white .. then epoxy/glass over after completely paint dry..<br /><br />just concentrate on a good external appearance an a good tite fit..<br /><br />when you epoxy in the drain plug.. that's it.. your only goin' thru 1/4 in. luan & foam sandwich..

 

[kempshark]

Re: Building a Fiberglass Cooler

Thanks for the info and advice. I don't know why I was thinking of the fiberglass insulation, just the first thing that popped in my head when you said pink and Owens. So, you're just using the luann on the outside and glassing right over the foam on the inside? Did you put any type of handles or latch on the one you built? Like I said, I plan on istalling a drain pipe (tube) with a ball valve and a hose fitting. That way I can screw a hose onto it, run the hose wherever I want, open the valve, and let her drain.<br /><br /> Now I just have to figure out the demensions for it. I'm thinking I want to make the interior volume the size of about a 200-250qt cooler. Maybe bigger, depending on weight of the finished unit. I won't be moving it often, but I'd like the ability to move it without enlisting a whole crew of people.

 

[kempshark]

Re: Building a Fiberglass Cooler

Anyone else ever try building a fiberglass cooler? Almost something like a dockbox, but insulated? I'm still trying to find other info and ideas for the construction.

 

[John Carpenter]

Re: Building a Fiberglass Cooler

As far as dimensions go...30" X 20" X 20" internal measurements will give you 208 qts. The largest you can get from a single sheet of ply (not counting the ends) would be 48 X 24 X 24 which would give you a capacity of 480 qts. (minus the thickness of the walls)<br /><br />For a cooler of this size which might contain quite a bit of weight, I don't think 1/4" luan will cut it. I would use 1/2" exterior grade and build each panel on a "ladder" frame using 2 X 2 or 2 X 4 stock,with foam between the rungs. Then put a second thickness of foam over all surfaces. Use extra bracing where the handles and hinges will attach. Since 2" stock actually measures 1 1/2" thick, you would have two layers of 3/4" foam to fill the rungs in, and then another layer of foam for a total of 2 1/4" of insulation. I would put it on casters Should be a hell of a cooler.<br /><br />To figure capacity: L X W X H in inches gives capacity in cubic inches. Divide by 231 to get gallons...then times 4 for capacity in quarts. Good luck with your project.

 

[kempshark]

Re: Building a Fiberglass Cooler

So, Relentless, you're also saying to use the plywood on the outside and just glass over the foam insulation on the inside?<br /><br /> I think my biggest challenge, other than learning to work with the fiberglass and resins, will be figuring out a way to make a tightly fitting well sealing lid. <br /><br /> Maybe I should build a smaller version just to figure out the best way to make it and to practice with the materials and the issue of designing the seal for the lid.

 

[John Carpenter]

Re: Building a Fiberglass Cooler

Kempshark: I think that if I were building something like this, and wanted it to last, I would glass it inside and out...or at the very least, use a good quality enamel on the outside.<br /><br />I know nothing about the fiberglassing end of this...like whether or not the resin would melt the foam etc., but it should be pretty easy to build. I would rip 2 X 4's down the middle to get 1 1/2" stock for the frame. Cut the panels to the desired size and screw the frames to the plywood. Screw it together and fill in the voids with foam. Glass as required.<br /><br />I think that on the ends where the handles will go I would use a full 2 X 4 in the center and through bolt the handles using t-nuts set in the wood on the inside. Maybe do the bottom the same way to attach casters if you are using them.

 

[djvan]

Re: Building a Fiberglass Cooler

My brother used an aluminum toolbox(like for in the bed of a truck), insulated with pink insulation, he replaces the foam every now and then to "freshen" it up. It works great, and looks good. In a pinch he can take out the foam and use it for other stuff. Lockable too. He didn't glue the foam in, just "wedged" it against itself(if that makes sense). I'm not talking about the full width toolbox, just a box that sits on the bed floor. About 30" by 36" by 24" tall.<br /><br />DougV>

 

[jimmythekid]

Re: Building a Fiberglass Cooler

Sam's Club sells a very large cooler, 4 feet long, by 3 feet wide by 3 feet tall, already has handles, and a well sealing lid. all this for about 17 bucks

 

[lawyertob]

Re: Building a Fiberglass Cooler

Originally posted by jimmythekid:<br /> Sam's Club sells a very large cooler, 4 feet long, by 3 feet wide by 3 feet tall, already has handles, and a well sealing lid. all this for about 17 bucks

I was thinking much the same thing. I was pricing glass at $5 a square yard...per layer...not to mention the resin for my transom repair...couldn't help but wonder how many $$$ would go into a fiberglass cooler.<br /><br />Just my $0.02 worth,<br />Joe

 

[kburks1230]

Re: Building a Fiberglass Cooler

sounds far inferior to a fiberglass cooler. $17 bucks for a cooler and $5 for warm drinks.

 

[Huron Angler]

Re: Building a Fiberglass Cooler

This 5-year-old thread got resurrected?......so did the 'glass cooler get built and withstand hurricane Katrina or what???

 

[oops!]

Re: Building a Fiberglass Cooler

lol......


if he ever did biuld it....it cost more than a new expencive one....even at 04 prices....

 

[giericd]

Re: Building a Fiberglass Cooler

2nd rebirth of the thread! i'm doing a cooler project right now. just a little fun thing to do but it will last a life time once done. there is no doubt that you can buy a good cooler for far less than to make a custom fiberglass cooler, but here in south florida you get a few years at most with even a "good" $200+ cooler before the UV rays kill the plastic and the cooler cracks. I'm done with it, i decided to build a cooler for a specific function and to get used to a material i have never used before. I am known for all ways having a coke in my hand and i wanted a small cooler that you can take one of those 6"x6"x15" coke 12 packs and fit it snugly in side and have it keep drinks cold all day with only putting in about 1/2" layer of ice on the all ready cold cans in the morning before i head out. I have a lot of experience with fiberglass and gelcoat but have never played with epoxy and carbon fiber and need to get some experience with this stuff. so my build involves 1/4" luna sandwitching 2" R-MAX foam on the sides and bottom and 3" on the lid. R-MAX is a polyisocyanurate foam so it can be used with poly resins and is super easy to use, great product and has a good insulating rating. fiberlgassed all around in side and out. then it will be gelcoated. then just to make it look cool and to get some experience using it i am going to use a gold carbonfiber hybrid around the sides. the carbonfiber will be cut so once in place there will be aprox 1/2" of visable gelcoat sorta like a border between the carbonfiber and the bottom of the cooler and between the carbon and lid. all work will be vaccum bagged. This should result in a near bullet proof cooler that will last a life time, keep drinks cols, and look good too. have any of you guys done a build similar to this or made a cooler with carbon fiber?

 

[JB]

Re: Building a Fiberglass Cooler

Not rebirth, giericd, Hijack. Please observe our rules about reviving old threads. It is frowned on.