Tuesday, January 11, 2022

How to Build a Cooler out of Foam Board

[You can also watch the video tutorial posted on my YouTube channel and/or view this photo album]

I would love to have one of the modern high-performance coolers, such as the rotomolded style, but we don’t actually need one badly enough to justify spending the money. But I wondered if I could build something comparable out of foam board for a fraction of the cost. 

So I built a small prototype, process described below, and here’s what I learned. I could NOT build a comparable cooler at a fraction of the cost. Nonetheless, I had a ton of fun and while the example I built would not stand up to the “Yeti” style coolers, it is quite functional and looks pretty great, IMHO.