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DIY Cooler

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It’s our first official day of summer vacation and I am so EXCITED! I’ve mentioned, many times before, how much I love entertaining in the summer!  Cook-outs, swimming, eating, time with friends and family – HEAVEN!  I’ve always wanted a wooden ice cooler for our patio and decided last week that I could totally build one!

Ice_BoxHere she is, my Country Cooler!  I’m so excited about this, not only because I have been wanting one but, I designed and built it myself!  It’s my first attempt at a piece this big and I’m happy to say that it is such a beginner project and only cost me about $50!  I will share a detailed tutorial with you here, and we now have FREE printable plans for this cooler!  Click HERE, or the button below to save or print the plans!

DIY Cooler Free Plans

Shopping List:

6 – 1×4 boards @8ft.

5 – 1×2 boards @8ft.

3 – 1×3 boards @8ft.

1 – 2×3 board @4ft. (try to find a scrap or buy an 8ft. board)

1 set of 2 1/2″ Zinc narrow hinges

1 – Rubber stopper with chain

1 – 6 1/2″ Zinc utility pull

silicone sealant

1 – sink flange

1 –  1/2″ U Bolt

1 – Ice scoop

1 – Zinc bottle opener

3 – Hooks

*I used cedar boards for everything except the 1×4’s on the main cooler surround.  I had scrap 1×4 furring strips so I used those. However, if I didn’t have the scraps, I would have made the entire piece with cedar.  It’s just gorgeous and great for outside!*

Styrofoam_CoolerI found this great styrofoam cooler at Wal-Mart.  I ordered it site-to-store, and it was ready for pick-up in about 4 hours!

Ryobi_Compound_MiterI used my Ryobi Compound Miter saw to make the cuts.  But, if you aren’t ready to purchase one, you can use the handsaw below for this project!

Front_and_Back

sidesStart by building the surround for the cooler.  I am going to share the measurements that I used for mine but, keep in mind that you need to measure and cut as you go.  Board sizes vary and climates can affect the boards as well.

8 – 1×4 @25 1/4″

4 – 1×4 @16 1/2″

8 – 1×2 @25 1/4″

4 – 1×2 @16 1/2″

Kreg_Jig

I attached the boards together using my Kreg Jig pocket holes!  Above, I circled all of the places that I drilled the pocket holes and notice that I drilled pocket holes into the 1×4’s only so some 1×4’s have pocket holes going towards both ends to attach to the 1×2’s.

Cooler_SurroundHere is the surround, assembled with Kreg Jig pocket holes and Gorilla Glue wood glue!

Boards_for_LegsNow for the legs!  I also circled where I drilled pocket holes into the 1×3’s.

Measurements:

4 – 1×3 @38 1/4″

4 – 1×4 @ 38 1/4″

Assemble_LegsAttach them with pocket hole screws and a line of wood glue!

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Next, I just nailed them to the surround with my new Ryobi AirStrike Cordless Brad Nailer!  This baby ROCKS!

Ryobi-AirStrike-Cordless-Brad-Nailer

 

LegsI put a few nails on the outside and a lot on the inside.  I also used lots of wood glue 🙂

Attach_LegsNow, just drop the cooler inside the surround.  it should be a snug fit!  If not, it’s not a big deal, we are going to brace the bottom!

The top should be flush with the top of the surround

Insert_Coolerand you will have a little space below.

Bottom_BoardsThis is where the 2×3 comes in.  Cut 3 – 2×3 @16 1/2″ and drill pocket holes into both ends of each board.

Attach_BottomJust attach with pocket hole screws and wood glue!

TrimNow to make her pretty!  Use 1×2 boards to trim the top, making the edges flush with the surround.  You will have an over-hang between the legs.  Measure for these cuts to get them exact and attach them with brad nails and wood glue!

Now for the top!

Trim_for_TopUse 1×2 for the trim on the lid and drill pocket holes into the ends of the 16 1/4″ boards.  Attach with pocket hole screws and wood glue.

Measurements:

2 – 1×2 @25 1/4″

2 – 1×2 @16 1/2″

Panel_Top

I attached the boards, for the top, with pocket hole screws.  I circled where the pocket holes should be.

4 – 1×3 @23 3/4″

4 – 1×2 @23 3/4″

The_TopNow, just attach the trim to the top with pocket hole screws and wood glue.  The top of the boards should be flush with the trim.

We need a drain still!

Flange_and_StopperI had the idea to use a sink drain kind of contraption and this was SOOOO easy!  I purchased a cheap sink flange and rubber stopper with a chain.

Insert_Sink_FlangeJust twist the flange into the spot where you want the drain (make sure the 2×3’s on the bottom are out of the way).  Twisting it will cut through the styrofoam.

Cut_StyrofoamI had to follow up with my knife a bit but this technique made it easy to get the exact size hole that I needed for the flange!

Silicone_Sealant

Cover_With_SealantNext, I “gooped” silicone sealant around the flange and dropped it back inside the hole.  Push it in snug and wipe the sealant that seeps out with a wet paper towel.

Attach_TopTo attach the top of the cooler to the wooden lid, just use a generous amount of silicone sealant to the top of the styrofoam lid and press it into the wooden lid.

Now for the finish!

Rustoleum_Dark_WalnutI brushed on 1 coat of Rust-Oleum Dark Walnut stain

RustOleum-Spar-Varnishand followed up with 3 coats of Rust-Oleum Spar Varnish in satin!  This is a great finish to protect outdoor pieces!  Make sure to give the suggested drying time between coats!

Picture-31To get the distressed edges on the finish, I just used my Ryobi Corner Cat!  It’s super easy to use and it’s light-weight!  I just ran over all of the corners and edges with it.

I got to excited to get this together and didn’t take a picture of the hinges.  They are super easy to install though!  I just two at the back of the lid.

Bottle_Opener

Do you love that zinc bottle opener?  I purchased it from Amazon!.  You can click the widget below to purchase your own!

 

Scoop_U_BoltI found this great ice scoop on Amazon, as well, and found a U bolt to attach it with!  You can click the widget below to purchase this same ice scoop!

U_BoltI just predrilled (using a drill bit that was the same thickness as the bolt) and hammered it into the holes 😉  If it isn’t a snug fit, I would use Gorilla Super Glue Gel to secure it.

I attached my hooks and handle and in the ice and drinks went 😉  It’s time to party!!!

Ice_Chest_Plans

Cooler_Plans

DIY_Wood_Ice_Chest

DIY_Cooler

How_To_Make_A_Cooler

Ice_BoxI’m just in love with this cutie!  We have already been enjoying it this weekend!  I designed this cooler so that the styrofoam cooler can be replaced as needed.  It just slides in and out.  The lid can be pulled off as well!  And, FYI, the cute kitchen towels are Threshold brand from Target 😉

If you love my Country Cooler, I would LOVE your pins;)

Remember, you can download and/or print our FREE plans for this cooler by clicking HERE!!

Thanks so much to Jay of Jay’s Custom Creations for putting all of Shanty2Chic’s original plans into printable plans for our readers!  You should check him out!  He has some pretty awesome projects himself!

Thanks so much for stopping by and Happy Summer!

~Ashley

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54 Comments

  1. Mary on August 9, 2016 at 5:46 pm

    My friend and I have talked about making this cooler for over a year and just completed them. We’re so pleased with our wooden twins! 🙂 Thank you for the great project and plans!

  2. Carlos Reyna on December 4, 2015 at 9:59 am

    Excelente idea, saludos desde México.

  3. dragontech64 on October 26, 2015 at 1:06 am

    I am going to have to make this, it is a great cooler idea for those of us who have trouble bending down. (My wife and I both have back problems)
    Howver, I think instead of a prefab cooler, I will put a ply bottom in, and cut sheet styrofoam to fit. Add some galvanized sheet steel, which is thin enough to cut easily, as a liner, install a drain, and this would be a classic design fit for the years to come!

  4. Dylan on June 21, 2015 at 8:23 pm

    So I’ve been wanting to do this for a while. We bought our first house last year and our first summer there I was dedicated to studying the CPA. Now that that’s all over with I finally had time. Only issue was my wife didn’t want something as a dedicated cooler since we have a deck in our townhouse and now a huge backyard…so after some modifications, here’s the end result! The top opens for a cooler inside but a table all other times! Looks like it’s going to upload upside down so apologies if that’s the case…I’ll try again if it does

  5. Kim Braatz on September 22, 2014 at 12:12 pm

    Did you distress the cooler (with you sander) before or after you applied the varnish? Thanks!

  6. Travis on December 18, 2013 at 6:13 pm

    Hey I just want to thank you for giving me this awesome idea! I actually made one for a pretty unique christmas gift! Added are some pictures of mine. I used the same idea for ice scoop and beer opener but used a hard igloo cooler and added my own touch of design to the lid a silver and gold sugar skull also i had a little lady bug friend while i was outside staining it. Thanks.

    • Belia Krouse on January 22, 2016 at 5:25 pm

      If you want to make it by yourself just go to woodprix page.

  7. Kay Farley Mayfield on September 18, 2013 at 10:10 am

    We love our cooler! We had some friends over this weekend and had three people ask me to build one for them. I started using your ideas to build decorations for our daughter’s wedding last fall and it has continued from there. Thanks so much for the awesome directions for the cooler!

    • Holly on May 23, 2014 at 12:33 pm

      hi. sorry if this is a dumb question. but I am confused by your shopping list. its has a certain # of 1×4’s for example. But when you scroll, each section has a new list? It just doesn’t all add up to your “main ” shopping list? How many of each board, total, do you need?

  8. Belinda York on August 29, 2013 at 6:55 am

    I just built this yesterday and I LOVE IT!! It came out beautiful! I ran into some issues as well with the cooler and the lid being larger than the opening, but I just used a large hand saw and cut the ends off to fit!!
    Thanks Shanty2Chic for the great idea and plans!! I may be building another one for a Christmas gift! I used all cedar wood for mine, when all said and done I end up spending $100.00 and I still need to stain and varnish it. LOVE IT!!!

    • Shanty2Chic on August 29, 2013 at 6:57 am

      So awesome Belinda!!! Wed love for you to email us pictures:). Thank you for sharing your experience! Great job!

      • Belinda York on August 30, 2013 at 7:03 am

        I will do that, I think it turned out great!!

  9. Sarah Lynn on July 29, 2013 at 10:07 am

    Getting the fixins to make this.

  10. Lindsey Hines on July 18, 2013 at 5:19 pm

    Alrighty….I’m waiting to put one more coat of sealant. BUT…I’ve run into a bit of an issue. I ordered the same cooler from Walmart however it’s slightly too large. Actually it’s not square like yours in the picture is so can you recommend a way to cut it down to size? The lid is too large too so I would need to cut it down as well. We were thinking maybe a blade of some sort so that we could keep a nice clean cut. Thanks in advance!!

    Oh!!! Regardless of the cooler issue the structure itself is AWESOME and my hubby and I are super stoked and proud of ourselves!!!

    • Shanty2Chic on July 18, 2013 at 5:30 pm

      Hey Lindsey!
      That’s so exciting!!! I’m not sure why there would be an issue with size but maybe the coolers are not all the exact same? I would get a steak knife and cut away at it. Cut slow and back and forth to make it smooth! Hope this helps:)

  11. Eva Maria Wood on July 12, 2013 at 5:58 pm

    This might be the coolest DIY project I’ve ever seen in my entire life. Amazing work!

  12. Linda Chapman on July 6, 2013 at 1:47 pm

    I’m starting this project now and have my wood cut. Can you give me the information on where to drill the Kreg pocket holes. .. How far from the edges… Thanks! Great project!

  13. Ginna on June 19, 2013 at 4:25 pm

    How would you attach the lid of the cooler if you went with a non styrofoam cooler? I love this by the way!

    • Nancy Anderson on July 17, 2013 at 10:44 pm

      Ginna, I made one of these last year on the fly and used a regular cooler. I attached the lid to the wood with a couple of small screws. Some lids are thinner so you may have to put an extra board or two across the inside of the wood top to allow the cooler to shut properly. I also used a piano hinge instead of regular hinges just because I like them better and it keeps them from getting slammed back when they open it. I framed mine in with 2×2’s so there was a good strong base and used 1×4’s on the bottom. I drilled a hole through the side and stuck a piece of pvc pipe in the drain and attached a brass spigot to the pvc to drain it because I figured I could attach a small hose to it in case it was somewhere I didn’t want to just let the water run free. I made a “ledge” in the front so you could actually sit a beverage while getting others. I made a shelf on the bottom so extra beverages or glasses, etc… could be sit and so I could install casters so I could move it easier. I have a bottle opener on it and I put two hooks, one on each side to hold small galvanized buckets. One for bottle caps under the opener and one for tabs because so many people save them. I’m attaching a pic or two to let you see the nearly finished project at that time so if you look at the one that is opened you can see the screws in the top corners but you could attach them anywhere as long as the screws don’t go through the top board. The only thing I do differently now is use my kreg jig, it makes them look so much nicer.

      • Tracy Smith on July 19, 2013 at 6:49 am

        I did mine out of a regular cooler too, still don’t have it finished, but that looks awesome Nancy!!

      • dragontech64 on October 26, 2015 at 1:10 am

        I like the shelf lip around. Something to set a glass on if you’re going to fill it from something in the coller! So handy!

  14. Erin Walleman on June 14, 2013 at 3:05 pm

    I am building this for a Father’s Day gift… I ended up short some of the 1×4 for the sides and had extra of the 1×2. … I figured out that I needed 4 more of the 1×4 for the sides.. 8 instead of 4. Maybe I read it wrong or something, too.. but I had extra 1×2 and was short 1×4. I am so excited to finish this!!!! I don’t have a Kreg Jig, so hopefully it will still turn out looking okay. Thank you SOOOOOO much for posting this and the directions! I am thinking these would make great Christmas gifts, too.

    • Erin Walleman on June 17, 2013 at 7:36 am

      I finished it and my Dad loved it! Thank you, again!

    • Faith on October 15, 2013 at 7:29 am

      I bought all the “ingredients” for a DIY Father’s Day present for my husband. Then one week later gave birth so we JUST started this project last night.
      We’ve run into the same problem though. I think there was a typo or something with the first set of measurments. It says 4-1×4 at 16 1/2 and I think it should say 8.

  15. Jeff Patterson on June 11, 2013 at 5:17 pm

    Great job Ashley and your drain idea is ingenious. This would be a great addition to our patio. Thanks for the step-by-step tutorial.

  16. Faith on June 11, 2013 at 12:37 pm

    Does the $50 include the cooler and how much did that run you? I want to put the materials together as a little DIY project kit for my husband for Father’s day. He’s wanted to make one forever but hasn’t had a good idea on how to go about insulating it. This is perfect. Did you get most of your materials at Home Depot and do you think I could find the bottle opener locally instead of online?
    I have a feeling he will “Texas” it up with Lone Stars though instead of the scoop and hooks. 🙂

  17. Katie Leahy on June 10, 2013 at 12:46 pm

    What kind/type of wood do you typically use for your projects? I’ve bought wood before at Home Depot and Lowe’s and it seems like there’s always a piece or two that’s slightly warped or bent. Yours always look perfectly straight! 🙂

    • Shanty2Chic on June 10, 2013 at 3:28 pm

      Hey Katie! We get our boards there too. We usually use whitewood pine but sometimes we upgrade to premium pine, depending on the project. We just dig and we are very patient when we look for straight boards. Sometimes I will take them all out of their shelf until I get to the back. A lot of the boards at the front of the line have already been tossed many times by others. Hope this helps!!

  18. Meredith LeRoy on June 10, 2013 at 12:16 pm

    I LOVE this!!! I am hoping I can convince my hubby to make one for us this summer!

    • Shanty2Chic on June 10, 2013 at 3:28 pm

      Thank you Meredith! Good luck;) Hope he says yes!

  19. Sandi Renteria on June 10, 2013 at 11:55 am

    Love this!

  20. FlowerpatchPam on June 10, 2013 at 11:18 am

    Another great DIY to put on my list, I need one of these to add to my back deck for summer. I just finished some iPad holders using your tutorial for that and painted them up. I am going to post them on my blog this week, they were fun. I made them as gifts.

    • Shanty2Chic on June 10, 2013 at 3:28 pm

      How fun!! Send us pics and thank you so much:)

  21. Nicole Zartman on June 10, 2013 at 10:27 am

    I keep seeing pictures of these all over the internet and haven’t been able to find any plans/instructions! I can’t wait to build it this weekend! Thanks for sharing!!

    • Shanty2Chic on June 10, 2013 at 10:36 am

      Glad to help Nicole! I couldn’t find plans ether so I gave it a try and I’m so happy with it! Enjoy:)

  22. lindsay on June 10, 2013 at 10:21 am

    Love this!!! I have just startdx “building: this spring and have already completed three of your projects! Adding this to my list! One thing I have found is the cost is always much higher than your cost. We live in a lower cost of living area, so I am surprised. I would LOVE a post on what your price for wood is. For example we pay 6.00 for a pine 1×4 at home depot. Is that a normal price? I am also looking forward to more videos. I received the mitre saw for mothers day! 🙂

    • Shanty2Chic on June 10, 2013 at 10:35 am

      Thank you Lindsay! We actually pay a little over $4 for our white wood pine boards! We rarely use the premium which is a little over $7!

  23. Jaime Costiglio on June 10, 2013 at 9:52 am

    Ashley another awesome build, love that it’s UP and OFF THE GROUND!!

  24. Kim Braatz on June 10, 2013 at 9:19 am

    Totally making this for a housewarming gift for a friend! Love it! (One for us too.)

    • Shanty2Chic on June 10, 2013 at 9:21 am

      Awesome Kim! Please send us pictures of them:)

  25. Cari Morgan on June 10, 2013 at 8:56 am

    It just doesn’t get better than that!

  26. Elizabeth Hoskins on June 10, 2013 at 8:27 am

    Great tutorial!! This would be perfect on any patio during the summer. I wonder if it would work well with a hard plastic cooler? Or would that be too heavy? Thanks for sharing 🙂

    • Shanty2Chic on June 10, 2013 at 8:50 am

      Thanks Elizabeth! It would totally work with a hard cooler. My hesitation with using one was that to get the kid to work properly it would have to be disassembled and it was more expensive by about $20. It would definitely work though 🙂

  27. astrollthrulife on June 10, 2013 at 8:02 am

    This is totally amazing. I love this idea. Great Tutorial. Be sure to link this up to my Inspire Me party this afternoon. This is totally inspiring. Hugs, Marty

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