How to Make a Cooler Out of a Plastic Barrel

Hack saw to cut the barrel

Using a plastic barrel as a cooler is a perfect idea for parties and social gatherings. Plastic barrels are inexpensive, durable and a long-lasting option for a cooler. An open topped with a lid or a sealed plastic barrel of any size can be used for this project. Choose a barrel with a minimum wall thickness of .18 inches, or 3/16 of an inch, for durability and reduced risk of cracking from the cold water. The project does not require many tools, and the tools used are commonly used household tools that can be borrowed from a friend or relative.

Things You'll Need

• Tape measure
• Marker
• String
• Vinyl tape
• Hack saw with fine-tooth blade
• Water
• Caulk
• Drill
• ¼-inch drill bit
• Ice
• Waterproof containers

Instructions

1. Measure 3 inches down from the rim of the plastic barrel and make a mark at that location on the side of the plastic barrel with a marker. Repeat at four or five locations around the barrel. If the barrel has a removable top, start from Step 5.

2. Tape a string around the barrel aligning the string with each of the marks. Use the marker and trace the string to create a straight line around the plastic barrel. Remove the string.

3. Cut along the line with a hacksaw to remove the top of the barrel.

4. Place vinyl tape on the outside edge of the top, cutoff piece and the top edge of the bottom piece of the barrel so the tape is half on and half off of each edge. Fold the tape over the edges to cover the sharp plastic edges created by cutting the barrel.

5. Fill the barrel with water to check for leaks. If there are any leaks, mark them from the outside of the barrel, drain the barrel and coat the leak with caulk after the barrel dries.

6. Place the top section back on the barrel. Use a drill with a ¼-inch drill bit to create two holes on the top spaced 2 inches apart aligned with two holes in the bottom that are spaced 2 inches apart. Place the holes on the top and bottom 2 inches from the edge of the piece.

7. Tie an equal length of string through each of the top and bottom holes to create a hinge.

8. Fill the barrel approximately half-way with water and add two or three bags of ice.

9. Put sealed cans or bottles directly into the ice or place in deep plastic dishes that can float on top of the ice water. Put items such as lunchmeat, cheese or other items that need to be kept dry in sealed containers and place in the barrel cooler.

Tips & Warnings

• Cover the barrel cooler with a thick blanket or moving pad to keep it cooler longer.

• Always drain the barrel cooler when it is not in use to prevent a drowning hazard for children and the water from becoming stagnant and drawing mosquitoes.

References

• Harbison Brothers: Plastic 55 Gallon Drums and Rain Barrels