Quote Originally Posted by newty View Post
My cooler will certainly keep drinks cold all day but I was looking more along the lines of having it keep ice for more than a day. Maybe 2.
Hey Newty that was my goal as well. After using the HVAC insulation and metal tape to seal, if i half empty the ice bag into the cooler and lay the rest it flat on top of the drinks in the bag i still have some ice at the end of the day, not much at all though. BUT, they stay real cold all day.

So after that experiment last year i got to thinking about the spray insulation in the can and how to use it. As you said above in your post making a mold but that's really not doable as you'd have to be able to access the cooler from all sides. BUT, what if you could seal all around with the foam? So here's what i'm going to be doing to mine soon.

Step 1: Figure out the thickness wanted of the foam and how far it will protrude out the sides or ends.

Step 2a: Mark off that dimension on the carpet and cut from the front to the back, essentially removing the carpet where the foam will be. Why, because for one you'll increase the thickness of the foam on the bottom and, if you don't you'll ruin the carpet anyway.

Step 2b: MAKE SURE cooler drain hose and clamp are in perfect shape and tight before spraying foam!

Step 3: Using spray foam insulation, fill in all areas under, in front and behind the cooler without spilling out the sides.

Step 4: After that foam has expanded as far as will go, place stiff cardboard pieces that you've previously shaped & precut precisely to close off the ends of the cooler. Block and support them with something heavy and spray the foam into the cavities through holes in the cardboard until it oozes out and around.

Step 5: Remove the cardboard after a while and then slyly using the wifes handheld chesse cutter, shave the foam to the desired shape and thickness.

Step 6: Cover the ends with something to protect the foam from chunking and chipping. My first thought was to coat the ends with resin and paint white. Not sure on that one.

Step 7: Cut out a piece of HDPE to fit in the opening, attach to the bottom of the seat.

Well there it is, let's have ideas to improve or whatever.