Note: The foam insulation and sheet aluminum measurements that are listed on the Material List are based on using 7/8″-thick cedar boards. If the thickness of the lumber you are using is different, then you must measure and cut the insulation and aluminum pieces to fit your 80QT cooler cart box dimensions.
1. Cut the rigid foam insulation pieces to size with a retractable blade knife and straightedge.
2. Cut the sheet aluminum using a circular saw. The safest and easiest way to make these cuts is to sandwich the aluminum sheets between two pieces of plywood. Use a standard universal-use circular saw blade to make the cuts.
3. Evenly space the bottom slats on the bottom sup-ports. Secure each slat with a couple of 1-1/4″ screws.
4. Place the bottom piece of insulation on top of the slats. Then apply construction adhesive to the back of the bottom aluminum sheet. This piece of aluminum is not cut to cover the entire piece of insulation because the front, back and end insulation will cover its edges. Center the bottom aluminum sheet on top of the bottom insulation and press to ensure complete contact.
5. Install the front and back insulation against the front and back panels. Similar to the bottom aluminum sheet, the front and back sheets of aluminum were not cut to cover the entire piece of insulation because the edges will be covered by the end insulation pieces. Apply construction adhesive to the back of the aluminum sheets; center them over the insulation and press into place.the edges will be covered by the end insulation pieces. Apply construction adhesive to the back of the aluminum sheets; center them over the insulation and press into place.
6. Install the end insulation pieces and attach the end aluminum sheets. These two pieces must be cut to fit exactly between the front and back of the cooler box.
7. The drain spout is made from three common plumb-ing fittings; a 1/2″ galvanized coupling, a 1/2″-dia. x 3-1/2″-long galvanized threaded nipple, and a1/2″ sillcock valve. You must bore a 7/8″-dia. hole through the side of the cooler box to install this drain spout. Drill a small (1/8- to 1/4″ diameter) starter hole through the aluminum sheet on the wheel end of the cooler box. Locate this hole approximately 3/4″ up from the bottom of the cooler box. Next, drill a 7/8″ hole through the aluminum sheet, foam insulation and end panel. Drill carefully through the aluminum to minimize tearing the sheet. Wrap both ends of the threaded nipple with Teflon™ plumber’s tape. Thread the coupling on one end of the nipple. Then slide the nipple through the hole in the cooler box. On the outside of the box, thread the valve onto the other end of the nipple.
8. Seal the interior of the cooler by applying a heavy bead of clear silicone sealant over all interior corner seams and around the drain coupling.
We are one of the cooler cart manufacturer and welcome to your consult!
