Fiberglass cooler/box build

jasoncooperpcola

jasoncooperpcola

God
I am building a mud quad, 2003 Honda Rincon. I want to build a fiberglass box for the rear rack. Three compartments. One in the middle being an insulated cooler big enough to hold a 12 pack of Bud Light and ice. The compartment on each side of the cooler will be for storage of straps, shackles, bungee cords for CanAm tie rod failures..... How can I build the lids to be waterproof? This box will be put underwater and I don't want muddy beer.

I am thinking the size will be 36" wide, 18" deep and 12" high. The cooler compartment will be the biggest.
 
Offhand I'd say that you should make a half inch thick top that's the same size as the outside dimensions of the cooler box, and then make a second half inch thick top that's the inside dimensions of the cooler. Marry them with glue/screws/whatever, then get some rubber tubing or some foam weatherstripping and glue it to the inside lip of the top so that when the top is
closed the rubber makes a seal against the top of the cooler edge. Attach hinges and a latch and you should be good to go.

Or better yet, send me the beer and that way you won't have to worry about it getting muddy or soaking wet. See? Simple fix...case closed. :beer:
 
Good idea Destroyer. I could probably layer it even further to make the seal better. Its been so long since I have researched fiberglass. Would a gallon and half of epoxy resin build it? Or should I go thru and build a mold to gel coat the box then build it from the outside in? I figured the 2" pink insulation board would be more than enough insulation on all six sides. Building it using epoxy I can use 1/2" ply stapled into the box form. Then glass inside and out? Add the insulation to the middle and epoxy over that with more glass?

What cloth would be good for this? Or mat? I can't remember! I have used the US Composites epoxy enough to feel comfortable using it so I am going with the US Composites epoxy resin.
 
And I am afraid I can't ship the beer as I probably would have drank it all before the shipping nightmare bs is done! I did discover apple pie last year. That's some good stuff....
 
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