Carbon Fiber Draft Beer Dispensing Stereo Cooler

For those who have ever floated down a river on a inner tube and dreamed of draft beer & good tunes.

Carbon Fiber-Draft Beer Dispensing-Stereo Cooler

Beverage Capacity: 2.0 Gallons

Stereo Play Time: 6+ Hours @ moderate volume

Electronics: (4) Infinity 6.5" marine speakers, Dual Marine MCP100 USB, SD (60 watts x 4 channels), Deep Cycle Battery (23 amp hr)

Note: Wheels are removed.

About this instructable: It was never my intention to post a detailed step by step construction guide, rather a general over-view of construction and lessons learned. I hope to see another like it on the river some day :)

Step 1: Carbon Fiber Draft Beer Dispensing Stereo Cooler

Outer shell constructed of 2X Owens Corning Foamular 3/4 in. (r-4) Tongue and Groove Insulating Sheathing. 3-M 77 Spray Adhesive and sheet rock screws used to hold pieces together until carbon fiber is applied..

Step 2: Carbon Fiber Draft Beer Dispensing Stereo Cooler

Dividing wall (1.5 in.) and backing for wheel well added.

Step 3: Carbon Fiber Draft Beer Dispensing Stereo Cooler

Styrofoam block inserted to fill dead space and provide level base for battery.

Note: I added 3/8" wood spacer between styrofoam insert and outer walls. logic being that it would give long term support for axle well. It is the only wood utilized and most likely was not necessary.

Step 4: Carbon Fiber Draft Beer Dispensing Stereo Cooler

Added outside wall for electronics compartment.

Step 5: Carbon Fiber Draft Beer Dispensing Stereo Cooler

After sealing joints, cracks, and holes, a simple primer coat was added. Thinking it was a good idea, I added dry wall corner molding to help give more rounded effect.

Note: This step was not required. I later added top cap which I carefully routered and shaped by hand. In short, end results looked great but added allot of extra time to the project.

Step 6: Carbon Fiber Draft Beer Dispensing Stereo Cooler

After sanding and floating corners, an additional 1.5 in. of r-4 board was added to accommodate the (4) 6.5" marine speakers.

Note: Cut a wire channel between layers for speaker wire from cooler side and any additional wiring. (external switches, battery indicator, solar wiring, etc..) Adding rigid tubing between layers would be helpful for future expansion and wire replacement.

Step 7: Carbon Fiber Draft Beer Dispensing Stereo Cooler

Once again float, sand, prime.

Step 8: Carbon Fiber Draft Beer Dispensing Stereo Cooler

Apply Carbon Fiber

Step 9: Carbon Fiber Draft Beer Dispensing Stereo Cooler

After trimming and sanding, a top base was added.

Note to self: Measure keg height prior to constructiuon.

Step 10: Carbon Fiber Draft Beer Dispensing Stereo Cooler

Carbon Fiber applied to top cap.

Step 11: Carbon Fiber Draft Beer Dispensing Stereo Cooler

Another layer of carbon fiber.

Step 12: Carbon Fiber Draft Beer Dispensing Stereo Cooler

After sanding and trimming, a layer of resin was generously applied.

Note: Retaining the carbon fiber look was never my intention, rather I wanted a smooth white finish. The extra cost of resin was applied to fill low spots.

Step 13: Carbon Fiber Draft Beer Dispensing Stereo Cooler

Satisfied that all voids and cracks were addressed, everything was once again sanded smooth.

Afterwards, cut outs were made for stereo head unit, 12v socket adapter (for charging battery), and (2) compartment drains.

Step 14: Carbon Fiber Draft Beer Dispensing Stereo Cooler

Decided to add a recessed beer spigot.

Note: As mentioned earlier, moving the spigot up an inch or two would have given needed clearence.

Step 15: Carbon Fiber Draft Beer Dispensing Stereo Cooler

Constructed and primed compartment doors.

Cooler side (shown): Layer of 3/16 plexiglass and two recessed layers of 3/4" r-4 board

Electronics side: Layer of 3/16 plexiglass and one recessed layer of 3/4" r-4 board

Step 16: Carbon Fiber Draft Beer Dispensing Stereo Cooler

First layer of carbon fiber on compartment doors. After resin cured, excess was trimmed, sanded, and second over-lapping layer of carbon fiber applied.

Step 17: Carbon Fiber Draft Beer Dispensing Stereo Cooler

Tires: 8" Non-Marring Rubber Tire
http://www.harborfreight.com/8-inch-non-marring-rubber-tire-47638.html

Axle: 5/8" SS tubing (local scrap yard) captured with on each side w/ removable pin. Simple 1/4" thick rubber wear gaskets inserted between tire and cooler as wear gaurd.

Axle Well: (forgot to take pic) 3/4" schedule 80 pvc. Sealed inside and out.

Step 18: Carbon Fiber Draft Beer Dispensing Stereo Cooler

Couple coats of marine paint.

Step 19: Carbon Fiber Draft Beer Dispensing Stereo Cooler

Couple coats of marine paint.

Step 20: Carbon Fiber Draft Beer Dispensing Stereo Cooler

Couple coats of marine paint.

Step 21: Carbon Fiber Draft Beer Dispensing Stereo Cooler

Mount speakers and run wiring.

12v cigarette lighter socket installed.

Note: 1/2" thick gasket was added to each speacker to provide adequate clearance. Yep... measure twice, cut once.

Step 22: Carbon Fiber Draft Beer Dispensing Stereo Cooler

View of installed speakers and 12v cigarette lighter socket.

Step 23: Carbon Fiber Draft Beer Dispensing Stereo Cooler

Install compartment doors and hindges.

Step 24: Carbon Fiber Draft Beer Dispensing Stereo Cooler

Install beer spigot and compartment door latches.

Step 25: Carbon Fiber Draft Beer Dispensing Stereo Cooler

Add vent covers to electronics compartment door.

Step 26: Carbon Fiber Draft Beer Dispensing Stereo Cooler

Electronics

Dual USB SD (60 watts x 4 channel) Stereo
http://www.dualav.com/marineaudio/mcp100.php

23 amp hr. deep cycle battery (Academy)
Note: Will replace this with a gel battery some time in the future.

Note: Electronics compartment was originally designed to house larger battery, small cooling fan, and 4-channel marine amplifier. After some consideration, I decided that portability (25+ pounds lighter) was more desirable that hair splitting volume. Given such, wheels could have been further recessed to allow proper clearance.