Building a Fishing Kayak Cooler #10: Making the Lid

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Blog entry by DustyMark posted 05-06-2019 03:34 AM 440 reads 0 times favorited 0 comments Add to Favorites Watch
« Part 9: Why Show a Fiberglass Intensive Project on a Woodworker's Site? Part 10 of Building a Fishing Kayak Cooler series Part 11: Fitting the Lid »

The construction of the lid is much the same as framing up the cooler.

Trace the outline of the lid from the cooler itself. I’ve experimented and the lid should compress the 5/16” gasket material down to 3/16”. Here I’ve cut 3/16” off the lid on the hinge end. This allows for the gasket.

Fit the 1/2” by 1” frame pieces.

I opted to use one screw at each corner of the frame. It’s tricky to line them up perfectly when the joints are 85 degrees. Thickened epoxy is applied to the lid frame.

Glue the frame to the top of the lid. Remember to glue in hinge tabs at this time. NOTE: Use a flat piece of 3/4” plywood as a clamping board. This will ensure the lid doesn’t form a twist. I failed to do this when building a skeg box for my wife’s surf kayak and it has a permanent twist in it that even warped the skeg itself.

Fit the foam as before. A vacuum does a good job of pulling a piece of foam out of the lid after dry fitting.

I had applied a seal coat of epoxy to the inside of the lid pieces, so I epoxied the second half of the lid cover in place.

Cover the screw heads with thickened epoxy. You can see that I used 1/4” Baltic birch plywood for the top and bottom of the lid for strength.

Next Steps

1. Round the edges of the lid.
2. Apply fiberglass to the underside of the lid.
3. Seal the rest of the lid with epoxy.

-- Mark, Minnesota

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