Introduction: Flat Pack Coolbox


I've made a coolbox with a twist. This coolbox is foldable!!

It's great for when your traveling! You can just fold it up so it takes up less space!

This project is great to learn to work with aluminum (cutting, bending).

Here's how I've made it.

Feedback is always appreciated :)

Step 1: Materials

Here's what you need to get started.

A sheet of aluminum that's 0.5mm thick (this is a thickness that's foldable.)

Some bolts to clamp it in place.

A set of rivets , I bought 100 which is more than enough! (The size of your rivets depends on the thickness of your aluminum plate)

And a piano hinge for making the door.

Step 2: Cutting the Baseplate to Size

First you mark all the cuts you have to make. I also marked where I have to bend the aluminum, this will help me in the next step.

Once you've marked all the cuts you than cut them using a cutter to score a little bit into the material and then bend it so it snaps off.

Step 3: Finishing the Baseplate

Once you've cut the aluminum you now have to bend al the sides up so you essentially create a box with one side missing.

Then you use the rivets to secure it in place.

(I also used some epoxy just for good measure.)

Step 4: Making the Side Pieces

Next you cut all the side pieces, punch a starter hole in them, then drill the holes for the rivets and bolts.

Rounding the pieces for esthetic reasons is possible, that's what I did.

I've cut all the side pieces out of one giant piece of aluminum, this reduces the material that's lost.

Step 5: Making the Isolation

For the inside of the coolbox, I used some PU foam and an isolating textile.

I cut a square out of the foam that is exactly the size of the inside of my previously made open cube.

I also wrap the textile in a cilinder and glue it together. Then I put the square into the textile and glue it at the wright spot.

This whole assembly can then go inside the open cube, where I glue it to the bottom.

Step 6: Making the Folding System

Next I assembled the side pieces together.

Step 7: Making the Top

The top is similar to the bottom but there's a hole in de middle so you can reach in de coolbox .

Step 8: Finishing the Isolation

You again use the PU foam and glue the fabric to it.

On the top you need a hole so again you could reach inside the box.

Step 9: Assembly

The last step is to assemble the pieces.

First you put the top over the isolation and glue it in place.

Then you use the rivits and washers to attach to side pieces and you're done!

Step 10: You're Done!

That's it, now you're done and you have your own flatpack coolbox.

Tell me what you think about it, feedback is much appreciated ! :)