Step 1: Gather Your Supplies!
Secondly, you need some sort of insulation. Again I got mine from the school, its from a project that no longer gets done so was going to be thrown out anyway. It's extruded polystyrene, better than that white polystrene as it's more solid. Ideally I would have like to used foil backed polyeurethene insulation (ie. Kingspan) but this was free and won't be that less efficient for keeping things cool.
I also used a pouch of Sugru, and when i find something suitable, I will use some sort of sealant.
Ok, on to construction...
Step 2: Chop Chop!
I made one big bit for the base and a bit the same size for the lid. Then I did each end and once they were cut, I cut the side pieces.
In order for the coolbox to have a good seal around the top, I also cut a part to fit inside the whole cavity, this would be mounted on the lid for when the box closes.
To cut the foam I used a bandsaw, and after years of using a hand panel saw to cut this stuff, the bandsaw was amazing! It didnt feel as though it was even cutting! (Be careful though, don't want to become overconfident! Remember, bandsaws were invented to cut up meat!)
I'm afraid you'll have to excuse the lack of photos, this is my first instructable and I simply forgot to take them as I was making the coolbox. Luckily, it's a simple build, so you shouldn't get too lost!
Step 3: Insert the Foam.
For the insert on the lid, I did chamfer the sides ever so slightly, just so it wouldnt catch as it swung into place.
Step 4: Happy Feet.
For this, i was going to use those felt pads you get for the bases of chair legs, but figured if you took the coolbox to the beach then they would pick up sand and defeat the whole point of putting them on. That's where the Sugru came into play. If you have never used /heard of Sugru it's a silicone rubber putty that sets solid after 24hrs, perfect for instructables! I got one packet which costs about a £1 and then split it into four equal sized balls and squashed them down on each corner. 24hrs later and they're totally solid and the coolbox is ready to rock!
Step 5: Finshing Touches?
This was my first instrucatble so any feedback is more than welcome!