Build a custom icebox

[Flint]

Hi everybody, Happy Holidays. This may be my first post to CF.

Has anybody on the site ever built their own custom icebox? I’ve been using a Coleman cooler on my PaceShip PY23, about 1.25cuft with block ice for the last couple years. Good for up to 4 days away, but I’d like to build a custom unit that would sit at the back of the cockpit and maybe last longer. Perhaps even include a cold plate for when shore power is available.

Foil covered Polyisocyan boards boast R7 or greater per inch sound good. A tight interference fitting lid on the top. Drain hole with plug. Some sort of waterproof liner inside (unsure what), and a durable exterior cover – maybe fibreglass, unsure.

What am I missing? Are there any pitfalls? Best assembly? I’m thinking 2 inches of insulation in the sides and top, and 3 inches in the bottom.

Any advice in planning this project would be appreciated – thanks
David

[montenido]

How about getting the biggest ice chest that you can fit and adding insulation to that? Everything would already be in place, like drains, lid, etc.

Good luck, Bill

[Roy M]

Flint, welcome aboard. As a first timer, you are forgiven for not knowing that many topics repeat over and over. In the upper right area of the header is a search function. Type in the key words for your search and enjoy the consequences. There are several threads devoted to this subject of building your own reefer or freezer. Few of them employ the technique you are suggesting, and they will explain why. It's mostly about insulation, first.

[Terra Nova]

Originally Posted by montenido

How about getting the biggest ice chest that you can fit and adding insulation to that? Everything would already be in place, like drains, lid, etc...

Though I've never tried this on the boxes I've built, it sounds like a good way to begin with a smooth, molded, interior liner. Insulation and vapor/IR barrier would be added to the outside. And the re-insulated lid would require its own hinge installation and latch.

[Flint]

Bill: Yup, thanks for that I saw a Youtube video with exactly what you're describing. It's tough to find a commercial cooler of a suitable size though. That's why I was thinking maybe custom all the way.

Roy: Thanks for the tip about the 'search' feature. I'm sifting through the results looking for others who have built their own ice chest.

One member has used Fibreglass sheets from HomeDepot as an exterior cladding - that sounds promising.

TerraNova - If I can find a commercial cooler of the right dimensions then you're right-on. The inside liner could be harvested for use in the new box.

[OBXSkipper]

Welcome Flint,
This is the most in depth icebox to refrigeration construction that I have ever seen. I kept the link to refer to when needed. Anyone who's ever been interested in beefing up their frig needs to check this out.
Marine refrigeration and freezer on 22 AH per day

[Emmalina]

Not that big a job ! We reinsulated our f/f system last haul out. Changed from polestyrene to closed cell panels then glassed the lot. 6" in the freezer and 4" in the fridge. Used waeco compressors... Go fot it

[Terra Nova]

Actually I would be inclined to use the entire cooler and add the extra insulation and barriers to the outside of both the box and the lid. By keeping the whole thing together you retain the strength and stiffness of an otherwise rather fragile inner liner.

There are so many cooler manufacturers/sizes/shapes/models available, and at all levels of quality and durability, that it is inconceivable that a near perfect choice would be hard to find. A tight fitting, gasket'd lid arrangement is preferred.

[zboss]

You could check out the engel drop in coolers.

Engel Coolers - Engel MB40 Drop-In

[SV THIRD DAY]

The foil lined polyisocyanurate board (R-Max) available from Home Depot is great stuff.
Buy some foil tape to apply over the cut edges as you puzzle the sheets of insulation together.
At R7 per inch...its the best bang for your buck at about $25 for a 4ft x 8ft x 1" sheet.

Getting it to the boat is always fun....I lost a piece on the freeway the last insulation project I was helping with....ugggg.....

[newhaul]

Originally Posted by SV THIRD DAY

The foil lined polyisocyanurate board (R-Max) available from Home Depot is great stuff.
Buy some foil tape to apply over the cut edges as you puzzle the sheets of insulation together.
At R7 per inch...its the best bang for your buck at about $25 for a 4ft x 8ft x 1" sheet.

Getting it to the boat is always fun....I lost a piece on the freeway the last insulation project I was helping with....ugggg.....

Rich that's the reason for having it delivered

[CAELESTIS]

Even if it survived the car ride, 25 knots in the dingy would cause a problem

See you at the Seattle Boat Show, Rich!

[UNCIVILIZED]

For custom glass work, it's easy enough to build a mold table. Including deciding what sized radi that you want on the corners, & then building them via a cove as part os the table, or using the right sized PVC pipe.
Then once you're done, just put a couple of good coats of mold release onto things, test it, & then get to cranking out your project.

But like's already been said, there are a million different types & style of coolers out there, with pre-built in cooling systems. Some of wich requires something as high tech as a cigarette lighter outlet, to plug them into.
So unless you have a wild desire to build your own unit from scratch, why not just pick up one already made, & add a bit of insulation to it?

PS: Just a "think": But, keeping a cooler out in the cockpit, where it's subject to direct heating from the Sun, ain't exactly the best option for maximizing how long it says cold.

[Delancey]

Easy enough to waste a bunch of time, materials, and effort if you make a mold without incorporating the single most important aspect of mold making for rigid fiberglass parts - draft.

https://en.m.wikipedia.org/wiki/Draft_(engineering)

All the mold release in the world won't do you any good if you have parallel faces or undercuts on your finished part.

[GordMay]

Greetings and welcome aboard the CF, David.