My boss at my final job requested me to make a picket cooler field and I agreed. Quick ahead 8 months and I’m simply now getting round to it. Many of the cooler packing containers you see on the market lean in direction of a country look. The aim for this one was to make one thing not-so-rustic as it’ll be topped off with a 12” round sports activities crew tin.
It’s a kind of initiatives that I’ve been randomly been fascinated by behind my head for a number of months. And in any case that point I actually didn’t provide you with any authentic design or concepts to include so the design I went with was not one in every of my very own. One of the best wanting design I’ve seen is from BeachBumLivin on YouTube in order that’s the place the inspiration for mine got here from.
To maintain the fee down I used common building grade pine 2x4s and some 1×4 furring strips. I additionally used two 3” outside hinges, three handles, some 1/2” PVC, two 1/2” PVC male adapters, one 1/2” PVC slip elbow, one 1/2” PVC elbow, one 1/2” feminine thread spigot, and a few PVC primer and glue. The cooler I used was a 52 quart Igloo model cooler.
To prep the cooler the entire handles and hinges have to be faraway from the cooler. My buddy Robert Blanford talked about in his cooler box video that you might promote the handles and hinges as a rebuild equipment for the cooler on Amazon or Ebay.
The primary little bit of building on this was to make a high body for the cooler to sit down in. I used 1×4 furring strips right here.
To make fast work of this mission I used pocket gap joinery for the construction. Every brief piece on the highest body obtained two pocket gap screws on every finish.
I generally get requested if glue is critical when utilizing pocket gap screws. Relying on the realm the place the pocket holes are for use it could or might not be vital however I all the time advocate utilizing wooden glue. It positive gained’t harm something.
A fast take a look at match within the body to see if it suits. The match must be good and comfortable so the cooler gained’t wobble round in it when the field is full. This body may even decide the general dimension of the mission.
I used common 2x4s for the structural body. You could possibly most likely get away with thinner materials equivalent to 1x4s although. I went with the thicker 2x4s to get a deeper recessed panel for the wavy trim I used to be going to make use of later.
Once more, pocket holes are used for the two×4 body items. My Foreman machine was already setup for 1-1/2” thick inventory so I used it as a substitute of my K4 jig.
Pocket holes positive do make the method go by rather a lot quicker. Two bigger frames are wanted for the back and front.
The 2 bigger frames are related with 4 shorter items. Every part was sized to match the perimeter of the highest 1×4 body I made earlier.
My authentic plan was to connect the highest body to the bottom with wooden glue and brad nails however I ended up not going that route to scale back the variety of nail holes exhibiting on the mission. As a substitute I used a small pocket gap jig to drill holes proper on the assembled body.
Wooden glue and 1-1/4” pocket gap screws have been used to connect the structural body to the highest body.
The unique drain was changed with a 1/2” PVC male adapter to present the PVC a connection level on the surface of the cooler.
The drain will finish and be managed through a 1/2” feminine thread spigot. One other 1/2” PVC male adapter will match into the again of the spigot. I drilled a gap within the decrease horizontal 2×4 body piece and mounted the spigot with a coupe brass screws from an outdated door deal with.
Common 3/8” pine plywood was used for the inside panels. I actually didn’t care how unhealthy the panels regarded as a result of I knew they have been going to be coated quickly. They only wanted to be glued and nailed into place.
The brief sides went in first adopted by the lengthy sides.
To safe the cooler within the body I wanted so as to add a pair decrease braces for the cooler to sit down on. I went with 2x4s for these items.
To make the cooler kinda maintain onto the two×4 bracing I used my sizzling glue gun to put a bunch of glue on the cooler earlier than including these braces. To safe them to the body I used two 3” wooden screws via the plywood panels.
The decrease shelf cleats have been produced from ripping a 2×4 in half. Basically it’s only a 2×2.
Extra 1×4 furring strips to make the decrease shelf. Wooden glue and a pair brad nails will maintain every little thing in place.
The lid of the cooler field is nothing greater than a 1×4 field. First a body is made tightly across the lid whereas it’s within the closed place on the cooler. Simply common butt joints with wooden glue and brad nails. Then a collection of 1×4 strips have been glued and nailed on high. Two 1×4 strips in entrance and in again with a smaller filler piece within the center. Every strip was not solely glued to the 1×4 body but in addition glued to one another. A pair brad nails on the perimeter will maintain every little thing down.
To safe the lid to the cooler lid I drilled 5 holes on either side and used 1-1/4” outside screws. This could maintain the lid with no issues.
I used two common 4” outside hinges for the lid.
One deal with for the lid and two handles on both finish to assist transfer the cooler field round.
Right here’s the place the BeachBumLivin inspiration comes into play. He has integrated a pleasant wavy line sample into a few his initiatives and that’s what I’m going to do with this one. I first ripped some 1×4 boards into 3/4” x 3/4” strips. Then I used the bandsaw to make a random wavy sample proper down the center.
I ended up making loads of them really. Every one needed to be sanded too. That was a extremely crappy course of.
My authentic plan was to make use of my pin nailer to carry them in place whereas the glue arrange however I ended up not needing to. I simply used a bead of glue and held them in place for a second.
I believe Steve Carmichael has a shirt that claims one thing like “Woodworking: 20% enjoyable, 80% sanding.” A number of sanding for this mission.
As a result of this mission will most likely find yourself outdoors I used a spar urethane by Cabot. I’ve by no means used spar urethane earlier than and I want I’d have completed a bit of extra analysis on the entrance finish. I didn’t understand it took 10 hours to dry.
The ultimate step was to attach within the drain items.
Ultimately I’m fairly happy with the outcomes. I actually like the best way it turned out and am glad I bought the chance to make one. I most likely wouldn’t have made one if it was for myself as a result of I most likely wouldn’t have used it. Hopefully yow will discover some inspiration in not solely this cooler field but in addition the one which BeachBumLivin initially made. I don’t have a set of plans for this however I do have a dimensioned diagram in addition to the SketchUp file obtainable for many who have an interest. Thanks for stopping by and have an amazing week of us!