Cool Box construction

[Jim]

I though seeing as I've finally got round to starting this, I might as well do a diary of progress.

Raw Materials;






Cutting the mortices for the joints:








One end assembled:





Just to show the finished size:




I've still got the tennons to cut on the four long battons; a job for tomorrow.

It's probably a bit over the top to cut mortice joints, but it's raining and cold and it's time I got a bit of practice in!

[Horden Hillbilly]

Aha, now we know what the timber was for!

Looking good so far Jim.

[Garth]

good work Jim, is this gonna be the type with fans and ice in?

[Jim]

good work Jim, is this gonna be the type with fans and ice in?

I have a gash upright freezer, and the box is going on the end of it. It'll also have a fan, a heater and an ATC800 to control them.

[BlightyBrewer]

I'm watching this with keen interest Jim. I am still debating whether to go down this route and extend my fermation chamber to fit cornies, or just buy a chest freezer and convert to a kegerator.

[Jim]

Progress update.

The frame assembled (it'll hold 2 barrels, or a barrel and an FV, for summer fermentation):


Detail of a corner joint:


The next problem is how to glue the joints and keep everything together (and square!) while the glue dries.

Ideas welcome!

[maxashton]

Duck tape!

Saviour of everything.

Or more seriously, you can get simple ratcheted clamps from most DIY shops for a couple of quid. They even turn up in poundland from time to time.

Failing that, you could bung some cyanoacrylate on there to keep it in place while the woodglue sets.

Or you could screw it all together.

[BlightyBrewer]

How about some gussets?

[Jim]

Clamps would be good, though I haven't got any big enough for this job, and I can't be *rsed to go to the shop.

Gussets could be the very thing, though.

[maxashton]

My mate (who is a cabinetmaker) says put a crossbeam across. "Just tack it to the outside, then take it off later."

[BlightyBrewer]

Big triangles are definitely the way to go for rigidity whilst it dries.

[Effigy]

Tack on corner to corner braces on all three planes.

[Jim]

Too late! I went for triangular gussets (fnar, fnar).

They did the job perfectly:

[Jim]

Latest news.

This is how it fits against the freezer:



The base:



For adjustable feet I've used coach bolts screwed into battons (the garage floor is very uneven, so it's essential:





I'm expecting condensation, so everything's getting sealed with PVA.



..which is currently drying off.

[Jim]

Thanks all for the suggestions earlier on. Nearly there now.

Insulation in place on fixed panels and all sealed up with mastic to prevent air leaks:



And with removable panels fitted (I need some sort of panel fixing to hold those firmly in place - I have draught-proofing rubber strip to fix on yet as well):