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Cedar Cooler Box

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Blog series by EdsCustomWoodCrafts updated 06-19-2015 10:35 PM 10 parts 15666 reads 6 comments total

Part 1: Materials & Tools & Sketchup Designs

05-04-2015 06:41 PM by EdsCustomWoodCrafts | 4 comments »

I decided to make a cooler box for my deck and I designed the whole project using examples from the web below are some of the design aspects that I designed on Sketchup.. Also is a shopping list for all materials and tools that I will be using in its construction: If you decide to make this cooler please take your own cooler measurements… As you know they are all very different, my cooler is a 48 quart cooler.. The cooler roughly cost me $100 for materials but I had to buy the K4 ...

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Part 2: The Legs & Stretchers

05-04-2015 07:11 PM by EdsCustomWoodCrafts | 0 comments »

The legs are constructed by connecting the following using pocket hole joinery: Take your 1×3 cedar board cut to 38” and place 3 pocket holes into the piece and connect to the 1×4 cedar board also cut to 38” ... Thus creating a L form or 90 degree angle … Do this process 4 times to create 4 legs…. The Stretchers are assembled by firstly placing 2 pocket holes at each end of the 1×3 and screwing them flush to the legs… There are 4 stretchers a...

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Part 3: Cooler Box Supports

05-05-2015 12:49 AM by EdsCustomWoodCrafts | 0 comments »

Next on construction list is the support for the actual cooler container to sit on….. For this part of the project I switched lumber type and dimension . I went with 2×4 Home Depots Wethershield lumber… I needed something with a bit more rigidness because they are going to be supporting a good bit of weight with the ice and all the beer for this 48 quart cooler. I used 3 pieces 1 for each side and 1 in the middle and again I used pocket holes to secure them…to ass...

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Part 4: Shelf Supports

05-05-2015 01:07 AM by EdsCustomWoodCrafts | 0 comments »

Firstly in order to put a shelf for a little storage I need to place shelf supports and I used 1×4 cedar again for this part of the build. I also decided that it would be more pleasing to the eye if I raised the shelf 3.5” off the ground as well as being a lot more functional and also avoid any unecessary ware and tear on the supports. The 2 supports were cut to size and I placed 2 pocket holes in each end and then hid the screws by screwing them into the leg L structure. ...

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Part 5: Shelf Construction

05-05-2015 01:23 AM by EdsCustomWoodCrafts | 0 comments »

The shelf will be made from 8 pieces of lumber ….(7) pieces of 1×4(1) piece of 1×3…. Each piece will be chamfered to essensuate each panel by using a chamfer router bit providing a 45 ° chamfer and I set the depth to about 1/8” on the router… Creating a very small v groove between each 2 pieces see pic 3 belowThe panel will be achieved by placing 2 pocket holes on each end of the piece going in 1 direct and then place one in the middle of them 2 holes goin...

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Part 6: Cooler Wall Part 1( front wall)

05-06-2015 12:06 AM by EdsCustomWoodCrafts | 0 comments »

When I designed this project using Sketchup I figured for this part of the project I would just construct the box and slot it inside the frame… I decided to scrap that idea and build each wall panel and affix it to the frame as I went, for 1 simple reason I could adjust each panel as I saw fit… Step 1. Cut all 3.5” panel to 13.5” length.. 7 piecesStep 2: run all panels through the router table using a 45° chamfer bit to define the panel further as seen in pic bel...

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Part 7: Cooler wall part 2: Right side

05-06-2015 12:20 AM by EdsCustomWoodCrafts | 0 comments »

All the panels are made and constructed with the same dimensions the only difference is the number of boards needed, since the sides are narrower than the front panels… Step 1: cut 4 pieces of 3.5” @ 13.5” lengthStep 2: run all panels through the router table using a 45° chamfer bit to define the panel further as seen in pic belowStep 3: pocket screw as beforeStep 4: attach panel using pocket screws and 1” screws into the side stretchers

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Part 8: Wall Panel : Part 3

05-07-2015 12:44 PM by EdsCustomWoodCrafts | 0 comments »

So it’s time to Finnish off the last two panels … The back and the left side…. That completes the cooler part of the unit and I have to say it looks awesome the pics don’t do it justice.. These last 2 panels were constructed in the same way as the front and right side panel using the Kreg K4 to drill pocket holes and there all held together with the 1 1/4” self tapping screws… I have to admit this design I made took a lot of screws I think if ...

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Part 9: Box Trim

05-07-2015 05:42 PM by EdsCustomWoodCrafts | 2 comments »

The reason I thought some trim would be a good idea was 1. It would cover all the wall panels joinery around the cooler..2. It finished the top part of the unit nicely and also provided a flat surface so as that the next phase and final phase of the project the cooler lid a flat surface to sit on3.and so as that I would also have more real estate to secure my piano hinge to, so as that the lid will open and close NEXT : Final part ” THE LID”

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Part 10: The Lid

06-19-2015 10:35 PM by EdsCustomWoodCrafts | 0 comments »

I provided a cut list for the lid components, the frame is made from 1×3 and vertical lid slats are 1×4…… I basically pocket screwed the top of lid together and while I was building the lid frame I incorporated upward pocket holes to screw into the lid….Then I screw the lid into the cooler using a piano hinge( continuous hinge)..At the end of the day every cooler is a little different dimensions wise so if your cooler is bigger/smaller the pieces will be different than mine … —Ed

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