Have you ever found yourself in need of a stylish solution for keeping your picnic essentials cool? While basket weaving could be an option, venture into something more durable and unique like a DIY cedar ice chest as per shown below. This isn’t just any cooler; it’s a handcrafted piece made from materials you might already have lying around, especially if you’re into woodworking. Cedar, known for its delightful scent and resistance to decay, makes this ice chest a timeless addition to any outdoor gathering.
DIY Ice Chest Project
Materials Needed
- Cedar fence picket cutoffs
- White oak pallet runner for corner pieces
- Wood glue
- Brad nails
- Foam insulation (from Lowe’s or similar)
- Green curtain (or any preferred fabric) for liner
- Plywood for the lid
- Polyurethane
- Super glue
- Piano hinge
- Brass handles
- Brass bolts and domed nuts
- Large washers or oak for backing plate
Tools Required
- Table saw
- Miter saw
- Hammer
- Chisel
- Speed square
- Thickness planer
- Biscuit joiner (optional)
- Router
- Utility knife
- Straightedge
- Hot glue gun
- Ice pick
Step-by-Step Creation Process
Step 1: Processing Material
Initiate your project by envisioning a simple yet elegant cedar box. Begin the transformation of the cedar pickets by ripping them into multiple strips using a table saw, which will later be arranged in a staggered fashion to mimic box joints. Utilize a miter saw to trim these strips to the desired length.
Step 2: Gluing Up Strips
Assemble each side of the chest by alternating between longer and shorter strips of cedar, employing wood glue to bind these pieces together. This method is designed to imitate box joints visually. Secure the arrangement by screwing scrap strips onto a workbench, using a wedge at the top to ensure a tight clamp. To avoid any warping, place heavy objects atop the setup while the glue sets.
Step 3: Trimming the Strips
Once the glue has dried, some strips might shift. Realign them using a speed square for guidance and a chisel to trim excess material, ensuring that each piece fits perfectly.
Step 4: A Change of Plans
Introduce the cedar boards to a thickness planer to smooth and even out their surfaces. At this juncture, you might find the initial plan to create box joints too challenging due to tight fits. An innovative workaround involves slicing off the excess material with a table saw, sidestepping the need for perfect joints.
Step 5: Corner Pieces
Fashion corner pieces from a white oak pallet runner into a double diamond shape. These pieces don’t just enhance structural integrity; they add an intricate detail to the chest. Attach these using wood glue and brad nails for a secure fit.
Step 6: Box Assembly
Create the base of the chest by joining cedar strips, optionally using biscuit joints for additional strength. Reinforce the interior walls with slim vertical cedar pieces, attached with glue.
Step 7: Adding Insulation
To elevate this cedar chest from a simple box to a functional cooler, line the interior with foam insulation. This step ensures your beverages and perishables remain cool, with the foam secured using a bit of super glue for extra hold.
Step 8 & 9: Liner and Lid
Enhance the interior’s appearance by lining it with fabric, attaching it at the edges with hot glue. For the lid, assemble additional cedar strips, reinforcing them with a perpendicular piece for structural integrity and easy identification of the lid’s opening end.
Step 10: Lid Insulation
Boost the lid’s insulating properties by affixing two foam “cushions.” This small detail makes a significant difference in maintaining the chest’s internal temperature.
Step 11-13: The Finishing Touches
Before finalizing your project, undertake a practical test with ice packs and perishables to assess the chest’s cooling capabilities. Follow this by sealing the cedar with multiple coats of polyurethane for durability and moisture resistance. For functionality and ease of movement, install brass handles, ensuring their secure attachment with brass bolts, augmented by an oak or washer backing plate for added strength.
Final Step: Celebrate Your Craftsmanship
With the handles and lid now installed, step back to admire your handcrafted cedar ice chest. This project not only challenges your woodworking skills but rewards you with a unique and practical piece perfect for any outdoor event. Enjoy the fruits of your labor and the cool refreshment it brings to every gathering.
This project is more than just about building an ice chest; it’s about imbuing a common gathering accessory with personal craftsmanship and style. The cedar ice chest stands as testament to the joy of making and the satisfaction derived from creating something functional, beautiful, and enduring.
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