Cheap Igloo Cooler Drilled, Filled and Hacked

[AreWeLostYet]

I have a 30 quart Igloo cooler from Dollar General for $20. It accommodates 22 lbs of ice with room for a few things. Room expands as ice melts. It's a nice compromise between tiny coolers that can only handle 10 lbs ice and monster 60 quart coolers that take two people (or dolly wheels) to haul. When I started covering it with reflectix, ice seemed to be lasting another day. I watched a few youtube videos where they cut coolers in half to see what's between the walls. The cheaper ones are often not well covered by foam. And the lid often has no foam at all. It looks like they must just shoot a little foam in the bottom of the outer wall, then press in the outer wall before the foam hardens on the assumption that the foam will expand to fully fill the area between the walls. It doesn't. Especially the top half of the cooler side walls have no foam at all. So I bought a can of aerosol foam meant to be used to fill cracks in your home's walls to fill areas where pests can get in you heat/cold can get out. I started by drilling holes in the sides - one hole per side - center/upper area large enough to get the foam sprayer's flexible nozzle tube into. I inserted the tube and sprayed away, waving the nozzle's end around to get the foam well distributed. Excess foam would begin extruding through the hole after extracting the tube. Maybe plugging it with something like a golf T would be a good idea. The foam that extruded out was easy to clean up since it dries to hard foam. But avoid getting the liquid on your hands of clothes as it is hell to get off - takes scrubbing with solvent like acetone to get off. Some of the videos I saw show installing a gasket with lid hold down mechanism like the high priced coolers.


What's inside a $400 vs $50 Cooler?


COLEMAN COOLER MODIFICATIONS


6 Genius Cooler Hacks

 

[AMGS3]

So, did you spray foam into the lid of your cooler too?

Also, have you noticed a difference between your cooler pre- and post- foam application? Does your ice last longer?

Thank
~angie

Sent from my VS501 using Tapatalk

 

[DLTooley]

The simplest solution is to put an inch or two of closed cell foam on the bottom of a cooler. The igloo marine cooler at around 50 is the best value.

I like your back, but I’m not sure how many holes it would take. That spray foam comes in either expanding or non-expanding. Too much expanding could destroy your cooler.

 

[Minivanmotoman]

Another hack, possibly cheaper, less messy would be to build a cooler with 1-2 inch xps foam sheets from HoDe.
Make one out of plywood or use Rubbermaid totes.
Some even fill their totes with spray foam and cut it out, line with plastic.
Or just make the box from xps foam and cover in PMF, poor man's fiberglass. Lots of how to online.

One could build a custom size box cooler to fit a specfic corner/ place/ section in your rig.

 

[DLTooley]

I’d first go with adding an exterior layer of XPS on an existing cooler.

That idea of a built in is intriguing. I wonder if you can buy a 12v compressor, or perhaps salvage one?

 

[crofter]

One could build a custom size box cooler to fit a specific corner/ place/ section in your rig.

This is a cool idea. Has anyone done this in their rig? 

I use an extra piece of insulation inside on top of the food, and then put a heavy canvas on top to make the ice last longer. This is with an old Igloo Ice Cube. The canvas adds an inch of insulation and some weight to keep the lid on tight.

~crofter

 

[Spaceman Spiff]

That idea of a built in is intriguing. I wonder if you can buy a 12v compressor, or perhaps salvage one?

Both Isotherm and Vertifrigo (and probably others) sell just the cooling units.  Cruising and sailboat forums will have some builds to check out.  Costs almost as much as a complete refrigerator.

I had good luck just rapping a cheap cooler in an old sleeping bag, putting a pillow on the cover and keeping it out of the sun.  Doubled the life of my ice.

 

[John61CT]

Yes complete 12V compressor kits, just add to your custom box are sold by hundreds of marine vendors, plug and play no technical knowledge needed.

Much more expensive than the OTS portable units, but great for getting more fridge / freezer space.

I've considered converting the passenger leg space to an ice box.

Here are some urls for those interested in learning more, sorry not clickable.

 

[AreWeLostYet]

So, did you spray foam into the lid of your cooler too?

Also, have you noticed a difference between your cooler pre- and post- foam application? Does your ice last longer?

Thank
~angie

Sent from my VS501 using Tapatalk

Hard to tell if there's a difference since my location/conditions/sun exposure have changed since the "upgrade". I did try and fill the lid. YOu can hold a flashlight beam on it in dark and see it's empty. I think you need to drill 4 or 6 holes to fill it completely. I just drilled 2. Spray too much of the "good stuff" in one place and it'll expand and you'll have a bulge in the cooler wall - towards the outside or inside or both.

One thing I have found makes a big difference is I'm buying a block of Ice, then pouring chopped ice over it. The chopped ice melts fast, but the block perseveres longer and I can chop off pieces with a screw driver for drinks. I also saw a youtube video where a guy tested drained and non-drained cooler. Surprising to many, but not me, draining the water made the ice last longer. But you could keep stuff cold longer leaving the water in. My theory is that liquid acts as a heat transfer medium between the ice and outer wall of the cooler, much like water in a car radiator transfers heat. But I like the ice to last. Cold drinks really help me handle the heat.

 

[AreWeLostYet]

The simplest solution is to put an inch or two of closed cell foam on the bottom of a cooler.   The igloo marine cooler at around 50 is the best value.

I like your back, but I’m not sure how many holes it would take.  That spray foam comes in either expanding or non-expanding. Too much expanding could destroy your cooler.

The problem I have with insulation inside (especially open celled foam which absorbs water)  the cooler is it's a place for mold and bacteria to multiply. Rather have a smooth-easily cleanable interior.

 

[AreWeLostYet]

This is a cool idea. Has anyone done this in their rig? 

I use an extra piece of insulation inside on top of the food, and then put a heavy canvas on top to make the ice last longer. This is with an old Igloo Ice Cube. The canvas adds an inch of insulation and some weight to keep the lid on tight.

~crofter

I've seen some youtube videos where they cut a piece of reflectix of plastic to lay over the food to limit circulation of warm air and keep the cold air in.