So i've been thinking about replacing my cooler mash tun for a while. I like the simplicity of the cooler but I don't like the idea of putting very hot liquid in plastic.
I thought about buying a kettle, putting it in a larger container and fill the void with foam. But it would be ugly. What I did is cutting small strips of 1" HD foam bought at home depot and tape them around my kettle. I then put two wraps of bubble foil insulation around it and finally covered the whole thing with strips of poplar. The bottom and cover are also insulated with HD foam. I added two latches in order to completely remove the insulation for cleaning purposes ! It holds the temps perfectly !
here's a close-up of the cover