Custom Fit Cooler Build

[Delicious Bass]

I've just finished building a custom cooler to fit the back of my Tarpon 160i.
I remembered to take photos along the way. Here's a quick run down...

Materials:
* 1" foam insulation board. (Lowes in Bowie sells foam boards that are not pink)
* Hot glue gun.

Steps:

1. Trace out the shape with a cardboard template.

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2. Once I got the shape right, plan for some space for some Plano boxes, plan where the vertical panels will sit.

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3. Cut out the bottom section. Make sure it fits...

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4. Cut out all the other bits. Side panels and top cover (2 parts).
The side panels are 6 inches. Tall enough to hold an aluminum can.

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5. Glue together with hot glue gun on medium temp. High temp melts the foam.

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Here it is with the tops on. Neither of the top sections are glued.

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[Shady]

Good idea! Curious to see how it holds up

[hookmeup]

"Cool" idea!

[mweber02]

Awesome idea! I bet you could coat it, maybe with fiberglass, to make it more durable.
I might have to give this a shot myself.

[Cowpokey]

I like it. Coating it with fiberglass is a great idea; inside and out.

[Delicious Bass]

I like it. Coating it with fiberglass is a great idea; inside and out.

Yeah... Fiberglass coating makes sense... Like a surfboard.... But I'm too lazy for that. Sounds hard.

I'm more of a duct tape type of guy. Maybe wrapping it in duct tape will make it better.

We'll see how long it lasts... I'll try to avoid sitting on it.

[Cowpokey]

I've never done fiberglass work, but I have watched someone do it. It didn't look hard at all. Maybe the guy I was watching had a lot of experience, I didn't know him very well.

How big is a sheet of foam board, what did it cost?

[Delicious Bass]

They come in 4'x8' sheets. 1" thick is $20 per sheet.

I bought 2 sheets for another non fishing related project ... But could spare a bit for making a cooler.
I think I used a little over 1/8th of one sheet for the cooler.

Looks like the hardware store sells fiberglass resin and cloth for about $25...

[Shady]

What about plastidip?

[Delicious Bass]

Wow. Plastic dip looks cool. I'd have to get brush on though. Aerosol propellant generally melts polystyrene foam fairly efficiently.

[yakPHISHn]

how bout that spray can rubber from the tv commercials where they make a boat with a screen door bottom?

[Yak Fish]

That's a cool idea. The Tarpon 160 is a sweet ride too.

[YaknBass]

nice idea...sounds like a marketing plan.. custom made cooler & fish boxes!!

[Memory Maker]

Yeah... Fiberglass coating makes sense... Like a surfboard.... But I'm too lazy for that. Sounds hard.

I'm more of a duct tape type of guy. Maybe wrapping it in duct tape will make it better.

We'll see how long it lasts... I'll try to avoid sitting on it.

It' actually simple .......... Get some fiberglass Mat ........... Cut it to fit. Doesn't have to be perfect ..... Can even use strips to layer if necessary. Just has to be tight w/o air space ......... Paint on the resin to soak the mat and squeegee out excess .... Let dry ........ Make a couple of coats and done ......... Just make sure you use the right resin. Some will melt foam insulation.

[mango]

Looks good and a great idea, +1 on the fiberglass coating.