Finished up my portable homebrew kegerator a few weeks back and after taking it on its maiden voyage I figured I would share it with you kind folk.
I've done the 1-keg in a cooler with CO2 injector and cobra tap thing and while that is handy, it's not the classiest looking way to bring beer to a party, nor does one homebrew keg last very long if >several drinkers are involved. The idea here was to build something that would be appropriate at any style party, whether it be a bunch of guys at a lake house or in the living room of a nice beach rental.
Using a wooden, frame-and-panel construction left the whole thing amazingly light yet sturdy but also created the obvious hurdle of how to make it water tight and proof. Several members here suggested fiberglassing the inside. I gave that a shot, but suffice it to say glassing is an acquired art and I was lucky to emerge without the project ruined and my poor brain in a fume-induced coma. In the end I decided to create a kind of internal box of aluminum flashing on top of 1" foam board insulation, which I sealed with aluminum tape and lots and lots of silicone sealant. The outside and top have a few coats of lacquer on them and will get a few more before all is said and done.
Another question I had when I was planning the build was whether to mount the taps on the front and force people to crouch or add a tower. I'm happy I went with the tower, as it reduces mess (no splashing on the floor) and makes it easiest to get a beer. The trick was to make the tower removable for transport. I settled on the old toilet fixture and bolts trick, using a floating wooden cover to hide the fixture.
Installing and uninstalling the tower is a piece of cake and so far I haven't had any problems with foamy pours because the ice keeps the kegs so cold. On long trips I have to replenish the ice every other day or so, and drain the water about once a day, so I included a drain with a garden hose fitting and a ball valve.
In the end, it work out even better than I could have hoped. Can't wait to bring it and some good brews to the OBX in a couple weeks.