'Super Cooler!'

[MarkG]

When I started yet another 'hobby/business' that required a cooler, and not owning one big enough or of the design I liked, I designed my own. It's not done yet, but you're looking at where it's at now. 4" thick foam walls all around----top, bottom, and sides. 4 re-freezable PVC ice-packs at the TOP where they need to be to take advantage of the laws of thermodynamics (cold air sinks) and I like how it works on a smaller scale in a 'store-bought' cooler I have.

The 2 sides at the ends of the tubes still get another layer of foam the same height as the other 2 sides. The inner (bottom) lid is shown pulled back a bit for clarity. The second lid layer will be glued to this one and lap to the very edge of the box. I used long nails at joints, not for strength, but to keep the parts for 'squirming' as they do with the adhesive on them.

2 sides still need the second layer of foam and I still am debating whether I want to 'laminate' the whole thing in 1/4" plywood or plastic laminate or something to add a little more protection from dents, dings, etc. Alternatively, I may cut out the foam for the outside layer incorporating the 'Pink Panther' logo on the foam as a decorative element!

An gaps left upon completion will be caulked inside and out, of course, but there are continuous beads of adhesive at all joints------gaps are because you can't squeeze the foam tight enough to close them without squashing the foam.