How to Build a Beverage Cooler
Keeping beverages cold at your barbecue can be a challenge. Ice chests may not be large enough, and barrels lined with black plastic may not fit your theme. Build a permanent beverage cooler instead. Based on the principles of old fashioned ice boxes, this beverage cooler requires no power. Does this Spark an idea?
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Things You'll Need
- 2-by-2 inch stock lumber for frame
- Miter box
- Back saw
- Carpenter's try square
- 32-by-32-by-2 inch thick sheets of Styrofoam
- 68-by-32-by-2 inch thick sheets of Styrofoam
- 32-by-32-by-68-inch metal box liner
- 18 feet of 2 1/4-inch wide, 2-inch deep plastic U-channel
- 3-by-6-feet sheet of 1-inch Styrofoam
- 3-by-6-feet sheet of 1/2-inch plywood
- 32-by-68 inch by 3/4-inch thick sheet of white Masonite
- 18 feet of 1 1/2-inch wide, 2-inch deep white plastic U-channel
- Carpenter's glue
- 1 box of 1/2-inch diameter, 3-inch long, galvanized steel wood screws
- Power drill, 1/4-inch drill bit
- Countersink bit
- Coarse, medium, fine and extra fine sanding belts
- Belt sander
- Clear silicone adhesive
- Clear acrylic wood treatment
- Two 3-by-3 feet pieces of 1/4-inch plywood for cladding
- Three sheets of 3-by-6 feet 1/4-inch plywood for cladding
Instructions
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1
Use a miter box and back saw to make 45-degree miter cuts in the 2-by-2-inch stock lumber, cutting two equal length pieces each time until you have four 6-foot long pieces and eight 3-foot long pieces. Apply carpenter's glue to the mitered ends of two of the 3-foot long pieces and two 6-feet long pieces. Push the pieces together firmly, as shown in the image that accompanies this step. Wipe away any excess glue and allow to dry for 1 to 2 hours. Repeat with the second set of two 3-foot long and two 6-foot long mitered pieces.
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2
Once the glue has dried, set one of the 3-by-6 feet frames on four upright 2-by-2 inch by 3-footposts. Use a carpenter's try square to ensure that all the mitered ends are flush and square with the corners and outer edges of the posts. Drill 1/4-inch pilot holes in the positions indicated in the image that accompanies this step. Countersink all holes. Secure the frame to the 2-by-2 inch posts using 1/2-inch diameter, 3-inch long wood screws. Repeat for the second 3-by-6 foot frame.
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3
Apply carpenter's glue to the inside surfaces of each frame section, as shown in the diagram that accompanies this step. Fit the Styrofoam sheets into the open spaces between the 2-by-2 inch frame, except for the top. Wipe away any excess glue. You should now have a 3-by-6 foot wooden frame made from 2-by-2 inch stock lumber, with the open spaces in each frame filled by Styrofoam sheets.
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4
Slide the 32-by-32-by-68 inch metal box liner inside the frame, flush with the edges. Use a miter box and back saw to cut the 2 1/4-inch wide plastic U-channel into two 3-foot long pieces and two 6-foot long pieces with 45 degree miter cuts. Apply carpenter's glue inside the U-channel and slip it over the edges of the frame and box to enclose everything. Apply a bead of clear silicone caulk to all the joints and smooth with a gloved finger.
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5
Apply carpenter's glue to one side of the 3-by-6 foot plywood sheet. Press the Styrofoam sheet onto it, making sure the corners are flush and square. This makes your partially finished beverage cooler lid.
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6
Cut the 1 1/2-inch wide, 2-inch deep plastic U-channel at a 45 degree angle, into two 3-foot long pieces and two 6-foot long pieces, using a miter box and back saw. Apply carpenter's glue inside each piece and wrap it around the outside edge of the beverage cooler lid you made in Step 5.
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7
Apply carpenter's glue to the space outlined by the U-channel, on the Styrofoam side of the cooler lid. Press the 3/4-inch thick white Masonite into that space, wiping away any excess glue. Place the lid on top of your beverage cooler and check the fit. The white Masonite board should extend inside the cooler just enough to keep the lid from moving easily.
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8
Secure the 3-by-3 foot sheets of plywood to the ends of the beverage cooler using 1/2-inch long, 1/2-inch diameter wood screws every 6 inches, beginning in one corner. Attach the 3-by-6 foot sheets of plywood to the sides and bottom.
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9
Sand all wood surfaces of your beverage cooler using coarse, medium, fine and extra fine sanding belts on your belt sander, in that order. Apply several coats of clear acrylic wood treatment, allowing each coat to dry 24 hours before applying the next one.
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Tips & Warnings
Do not operate any power tool when tired or while under the influence of prescription or over-the-counter medication. Do not operate any power tool while under the influence of alcohol.
