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Old 05-09-2007, 07:11 PM   #1
KEYSKILLER
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custom fishbox/cooler

i want to make a custom fishbox/ cooler. have the basic knowledge. glass, foam, resin, just looking for some tips/knowledge on what to attempt, what to avoid.

what thickness of foam?

thanks in advance.
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Old 05-09-2007, 07:29 PM   #2
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Re: custom fishbox/cooler

One of dagodiver posts on the subject.


http://www.spearboard.com/showthread...hlight=styrene

Quote:
Originally Posted by dagodiver
2" foam works fine.
I would for a few reasons forget the plywood all together, to heavy and does not hold fasteners very well.
If you want to thru bolt (best way) use the SS sleaves that they sell just for doing this and put washers on both sides, they will never pull thru. Alot of people dont like to fasten the top at all.
Use a good quality Iso layup resin and some 1 1/2 oz mat.
Use radius's everyplace that you can to avoid air pockets.
Use gelcoat that does NOT have wax in it and spray PVA over it to get it to dry as this will make repair work down the road alot easier.
DO NOT put sanding aid in any of the layups as this will kill the secondary bonding of the glass/resin.
Also dont let anyone tell you the epoxy is better for this because it is not.
Epoxy has no styrene in it to brake down the binders in the mat which makes forming it around corners almost impossible.
The brass boat drains work great and I have the tool for flaring the ends if you need to use it.
Have a great time.!


Dago.

Last edited by WreckDiver; 05-10-2007 at 07:57 AM.
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Old 05-10-2007, 07:30 AM   #3
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Re: custom fishbox/cooler

2 inch foam is good. You could make it out of foam completly, then fiberglass it, or you could make a frame out of wood, and then fill the sides with foam panels then glass. I have done both, and if your glass work is good, then no problem. I would use epoxy, especially the inside, but all over is better. Use white pigment for the last, final coat. The top should fit down into the box, I used 2 steps, both with weatherstripping. Also the top had a piece of plywood for cutting bait, filetting fish etc.
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Old 05-10-2007, 03:07 PM   #4
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Re: custom fishbox/cooler

I used 3 inch and it was probably overkill. Forget any wood unless you want it on top to cut on. I used plastic coathangers cut into 6 inch pieces to hold the foam in the box shape, like nails until i could get a hardened layer on it. Once you have 2-3 good layers of glass inside and out you it is VERY strong. No need for a wood frame. I gel coated mine inside and out as the last coat after I had enough glass layers on it.
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Old 05-15-2007, 12:55 PM   #5
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Re: custom fishbox/cooler

Have been reading posts on this site for years, but finally had to register after reading this thread. Actually I bought my current boat from a member that posted it for sale here (Catbox). Am considering building a custom fish/ice box for it and am curious if the cost is close to just buying a Frigid Rigid or similar box. How much did the materials cost for some of the boxes you guys built. I'd like to make something in the 300qt. range. Not looking for something pretty just functional. Thanks
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Old 05-15-2007, 09:27 PM   #6
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Re: custom fishbox/cooler

460 quart (approx) measures 5' x 2.5' x 2' outside, made from 2" foam with 2 layers (3 in some key areas) of mat and polyurethane foam cost me ~$550. It took ~1.5 gallons of resin, 2 - 4x8 sheets of 2" foam board, cloth, and some time.

An equivalent IceyTech etc does not exist. a 280q or so costs about $550, so I'm double the size at the same price.

It'll hold ice for days, you can jump on it with tanks on, use the top to cut bait or rig your dive gear, and when it gets scratched you can repair it with the material left over. I did manage to break it once when my buddy dropped it on a sharp edge of cement, but again, it was cake to repair.

No need for any wood, screws, etc. You just need something like long nails or equivalent to pin it together until the first layer of cloth/resin sets up.

Oh yea...we kept the lid simple. Imagine a shoebox lid, but made out of 2" thick foam board. No hinges, just lift the whole thing off. You can lift just one side to throw fish in if you want.

Last edited by kaborkian; 05-15-2007 at 09:35 PM.
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Old 05-25-2007, 08:52 PM   #7
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Re: custom fishbox/cooler

have the weekend off and its blowing so no diving. decided to start my fish box. THIS PROJECT SUCKS.

between cutting the foam to correct proportions to the resin, all around SUCKS.

makes me wish i spent the $500.00 on the icytec.

will post pics of finished project. if i dont run it over with my truck. might stick to the tires.
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Old 05-25-2007, 08:55 PM   #8
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Re: custom fishbox/cooler

haha now i cant wait for the pics.
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Old 05-25-2007, 09:04 PM   #9
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Re: custom fishbox/cooler

I know nothing about it, but I've heard glass work sucks! I am looking forward to the pics.
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Old 05-25-2007, 09:50 PM   #10
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Re: custom fishbox/cooler

here are some previews.
i got a sheet 4X8 2 inch fiberglass encapsalaed(SP) foam for FREE.
this is the largest box I could make out of the sheet.

it measures 40lengthX22widthX18height

i can guesstamate how many lbs it will hold, but does anybody have a formula.

tommorrow more glass, resin for the outside and paint. buy the way THIS SUCKS.

oh ya pair of costa's down
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Old 05-25-2007, 09:54 PM   #11
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Re: custom fishbox/cooler

Although the work may suck, it looks like you're putting together a very solid cooler.
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Old 05-25-2007, 10:00 PM   #12
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Re: custom fishbox/cooler

Hahaha guess no boat tommorrow hahah! We'd be crazy to freakin go out tommorrow if its blowing like this Brad. Call me if you want any help on the cooler. I got nothing to do all day.
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Old 05-25-2007, 10:06 PM   #13
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Re: custom fishbox/cooler

yea not going out tommorrow. it supposed to lay down for sun, i think 15-20.
i will get vis reports tommorrow and if there is any vis left, were going.

about the cooler, if you "have nothing to do tommorrow" i could use some help. kinda that karma thing i think you need to spread it around.
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Old 05-25-2007, 10:12 PM   #14
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Re: custom fishbox/cooler

Yeah well that wan;t what i was aiming for i was just offereing it up but i guess thats good karma! never really thought about it.
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Old 05-25-2007, 10:14 PM   #15
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Re: custom fishbox/cooler

call me tommorrow.

pics to follow.

corey fiberglassed to the side of the cooler, by accident
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