how to build a custom cooler

T

tfret

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Okay, I want to build a cooler that will fit between the two seats in the open bow area. I want to make a padded lid that will match the seats on both sides. When complete, the whole open bow area will one large padded seating area, with storage under the original seats, and a cooler under the middle area. I started to just buy a cooler with the closest dimensions and build everything around it. But that would leave wasted space. To make the most of the total area, I'd like to fabricate my own custom dimension cooler that would make use of every inch of space. Some type of thin plastic sheet material that I can cut and epoxy together is what I'm thinking might work. Then I can isulate around it. Any suggestions on what might work best for this?
 
You can buy PVC sheet at plastics dealers ( Piedmont Plastics, GE Polymershapes, and in some glass shops, and maybe a big box store ). Cut and glue the PVC. Then fill the gap around the new "well" with two-part marine foam. Note that this pourable foam is -expensive-. About $50 per expanded cu ft.

There are other methods, but that is the first that comes to mind...
 
If the area you want to fill has basic flat areas then I would use the pvc sheets as mentioned and fill with foam. If everything is curved in different directions and you want to max. the space, then its a fiberglass job. You would need to make a male plug of the area you want to fill and layup fiberglass with a foam core sandwiched between skins of fiberglass. If you not familiar with fiberglass fabrication and making the plug, it may be a challenge. Also, foams have different densities and different thermal insulation properties, so make sure you use the best one for your application. If you plan on putting cushions on top of the cooler for seating, make sure the lid is strong enough to support several people.
 
Easiest way is to start with a piece of plywood, cut to fit the aft opening and just start glassing it in. The thickness of the plywood depends on the size(width) of the opening it has to enclose. Insulating it brings it own complete new problems.
 
I would make this cooler like a bathtub and drop it in. The inside should have a gelcoat surface for your food and beverages. You will also need some system to drain the water as the ice melts. I agree with chesapeak, use divinycell or other pvc foam board.
 
The proposed area is basically a rectangle with 3 verticle sides, and the forth (front) side tappers up at a 60* angle or so. I think just making a box out of some type of plastic material would be easiest. I can foam the area around it and just drop the box into place. To avoid drilling a hole in the floor and trying to fish a drain tube to the rear of the boat, I'll just fab handles so the whole thing can be lifted out to dump out the ice and water. Functionality and simplicity. I'll have to google divincycell and see what that is.
 
What about when you go to sell? All that foam will not be removeable & most prospective buyers will probably shy away from a rube goldberg setup.
Al
 
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