Big Wheel Beach Cooler

I needed bigger wheels on my cooler to be able to use it on the beach and carry some extra stuff on top of it for camping (Hammock's Beach, NC).  I considered making a beach cart, but this was a cheaper option for me and hopefully will take up less space in my car.  I hope someone can give me some ideas on how to make an even better version in the future. I already have some ideas...

The costs include a $30 Coleman cooler from Wally World (Walmart), two 10" pneumatic tires from Northern Tool at $10/each, $3 worth of 1" schedule 40 PVC, $3 for some bathroom caulking, $2 for two cotter pins, and $10 for a 3' piece of 5/8" zinc platted steel rod from Lowes.  I like the cooler for camping because it holds ice a long time, so I figured an up-fit would allow for me to use the big tires on the beach and the factory tires for my everyday activities. 

I thought about buying the big grey beach wheels, but they were $50 to $60 each. 

Step 1 Cooler with factory wheels removed and drill holes marked

I popped off the factory wheels, and measured on the cooler where I wanted the wheels.  The wheel location had to allow the cooler to sit up straight normally while providing the maximum clearance when the cooler is being rolled.  The holes had to be drilled to only put a hole on either side of the cooler, without hitting the internal walls.   I wanted the PVC carrier pipe that I put in the holes to fit snug against the inside walls also. 

You can see my measurements on the cooler, and I used a 1" drill hole punch to put in the holes.  I pushed a piece of 1" schedule 40 PVC through the holes to create a carrier pipe for the rod that I used to mount the wheels to.  I caulked around each side of the holes that were punched through the cooler, even though it was a very snug fit. 

I cut the steel rod for the tires to a length that fit best for my use, and drilled a hole in each side to allow for placement of the cotter pin.

Comments

[tchiarito]

Thanks, I have been thinking of doing this with my cooler, same model as yours. One part confuses me a little: you said "The holes had to be drilled to only put a hole on either side of the cooler, without hitting the internal walls", but do I see the pix show the pvc going all the way through the cooler, or am I looking at it wrong? Thanks!

[Sman510]

The "internal walls" that I was trying to protect, was really just the walls on the inside of the cooler other than where you drill the hole on either side. I was trying to drill the holes as close to the internal back wall (where it is rounded a bit near the tires and the drain plug) of the cooler as possible, so I was concerned that the drilled holes may cut into the adjacent internal walls of the cooler. The PVC that I pushed through after drilling the holes fits tight against the internal back wall of the cooler, though that really isn't too important other than just trying to minimize the amount of space it takes up inside the cooler. I hope this helps clarify that statement, but let me know if you want me to try to give you a little more info.

Have fun. I really like the new wheels on mine.

[tchiarito]

Thanks, that clears it up completely. I plan to make the changes next weekend before my next camping outing, where. like you, I have to hike a mile along the beach before reaching the wilderness camping area.

[9w2xyz]

Have you considered wheel barrow wheels? Dirt cheap.

[tjesse]

Sand just eats the stock wheels for breakfast. Its like dragging a brick! Good job!

[Sman510]

That is a spot on analogy.

It would be funny to see one of the companies that makes those furniture moving pads create a parody commercial where they re-purpose their product to help people drag their cooler on the beach when the wheels can't cut it.

I appreciate the feedback.

[tjesse]

Why did you not mount the pvc to the bottom with C clips.

[Sman510]

I did think about putting the wheels lower originally, but would have had to add some type of stand on the front under-side of the cooler to allow it to sit up when at rest. I had not thought of what I would use to mount it that way, but if they were mounted securely, I think C-clamps would have probably worked well. The weight of the wheels and the bumps that I took the cooler over probably would warrant more than just using screws to attach them, but C-clamps could have done the job.

The wheels could have also been attached to the back of the cooler, so that it could sit up straight at rest. That would have changed the center of gravity, but as long as you weren't carrying too much, the cooler would probably still be pretty easy to maneuver.

[mikeasaurus]

nice mod, and the steel axle all the way through will allow some heafty loads to be carried.
Have you taken it out to the beach/camping yet, how does it perform?

[Sman510]

I just added some pictures from the trip I just got back from to the post. I was really happy with the results. I was actually planning to carry my pack, but realized when I got out to the beach, that I could put it on the cooler and have no problems carrying it. That made a huge difference.

I really just wanted the big wheels for this trip, since I had to hike a decent way in the heat. Now that I know that it can take some extra weight, it is going to be great for carrying extra beach chairs, umbrella, and the horseshoe set for future trips.

Thanks for checking it out.

[zazenergy]

Very nice mod! Thanks for showing us how this works.