My Latest Project - Walk-in Cooler

[TxBrew]

Very nice work! Have you figured out what you have into the project total?

 

[John Beere]

Sorry I went AWOL. In my absense, I modified the AC to include seven small (40mm) 12v fans in the front grill which constantly draw "warmer than freezing" air over the AC coils. Right now I have the fans running 24x7 but will probably start experimenting with different cycles soon.

The fans have completely solved all moisture problems by keeping ice from building up on the coils. Notice in the second picture the ice buildup on the AC coils. This ice is now completely gone.

 

[John Beere]

Here is my best guess at the materials used. Remember that I built it with quaility in mind rather than a fixed budget... although I had guessed it would cost around $1,000 total.

$250.00 (1) 12k BTU AC
$50.00 (1) Ranco Controller
$300.00 (30) R5 insulated board
$160.00 (4) R30 Insulation
$70.00 (14) 2x4x10
$20.00 (1) 5/8" MDF
$30.00 (1) 24" Door
$240.00 (8) 4'x8' wall board
$180.00 (60) Tube adhesive
=========
$1,300.00

 

[medtech]

you used 60 tubes of adhesive??

 

[John Beere]

you used 60 tubes of adhesive??

Yeah, a tube was only about enough for one 4x8 sheet of insulation - and I used all 30 sheets plus then glued the wall board on top. I also had to build the door, etc... There are no screws or nails holding the inside of the cooler together beyond the very first layer of insulation - only glue - so I used a lot...

 

[Scalliwag]

This is pretty hardcore brew-love to do a project this big. I read the whole thread and was beyond impressed. How has this played out on your electric bill? I read the post where you calculated about $12.50 in electricity per month. Has that seemed to be the case though? The initial investment and all the work is a bit, but not bad. But the most impressive part is it seems to be incredibly inexpensive to maintain.

 

[Pedro-]

This is amazing. I have ideas for this type of project when we finally get our own place.

I'm curious if you had thought about a slotted plastic sheet (rather thick sheet of vynl or the like) in the doorway to keep as much air in as possible when going in/out.

Nice job! Cheers!

 

[Brewtopia]

Congratulations! I just received my latest issue of Zymurgy and have read the article on your walk-in cooler. Very cool!

had the opportunity to make one final edit to the article and just put another plug for HomeBrewTalk.com back in the article... we'll see if it makes it!

And your plug for HBT made it!

 

[John Beere]

Sorry I haven't replied... work and the holidays have kept me away. The cooler is doing great and I haven't really noticed any increase in my electric bill what-so-ever.

 

[John Beere]

Congratulations! I just received my latest issue of Zymurgy and have read the article on your walk-in cooler. Very cool!



And your plug for HBT made it!

Its out already? Sheesh - I don't even have a copy yet!

I'm really nervous to see how much it was edited for print...

 

[John Beere]

This is pretty hardcore brew-love to do a project this big. I read the whole thread and was beyond impressed. How has this played out on your electric bill? I read the post where you calculated about $12.50 in electricity per month. Has that seemed to be the case though? The initial investment and all the work is a bit, but not bad. But the most impressive part is it seems to be incredibly inexpensive to maintain.

Yeah, that was August... I bet it isn't costing me $5 during the cooler months. Its rare I even here the A/C turn on...

 

[John Beere]

This is amazing. I have ideas for this type of project when we finally get our own place.

I'm curious if you had thought about a slotted plastic sheet (rather thick sheet of vynl or the like) in the doorway to keep as much air in as possible when going in/out.

Nice job! Cheers!

I thought about it and was even going to experiment with it but the way I did the thermostat seems to allow the air to exchange and not instantly kick on the A/C. I bet it gets opened several times a day as we also are using it as a spare frigerator (all our cokes and stuff are in there too) and it doesn't seem to effect it at all.

 

[scorpio_fl]

kool beans...Great project...read about you in zymurgy...you guys got it going on...read your whole blog...signed up on hbt...well organized project...buddy brown nfbl, tallahassee fl...

 

[RichBrewer]

Great project John_Beere. I also saw it in Zymurgy and it was awesome. I must say I feel star struck with folks getting published in national magazines.Between you and BrewPastor HBT is well represented.

 

[breyton]

AC.

Update on the AC: I test wired a new Ranco controller into the AC this evening. This was the step I was most worried about and, now that its done, I can't believe how easy it was... I was able to completely bypass the built-in controls on the first try. I will officially re-wire it tomorrow. The diagram at http://franklinbrew.org/members/sj/walkin.html is correct, even for my brand new AC.

Not sure if anyone has already asked this question, but is it possible to just change the existing temp controller in the AC unit to allow it to go down past the 40F limit?

 

[John Beere]

AC.

Not sure if anyone has already asked this question, but is it possible to just change the existing temp controller in the AC unit to allow it to go down past the 40F limit?

I think it might be possible with an older unit but it would be a crapshoot on the exact temperature. Newer units are microprocessor controlled and I would have no idea how to reprogram it to do lower than 60... especially when an new Ranco is only $50 on eBay.

 

[Biermann]

Hey, congrats on the Zymurgy article! I just got my issue. I instantaneously recognized the pictures and the setup!!

 

[Orfy]

Any one fancy scanning a copy? pleeeeeeeze!

 

[John Beere]

Any one fancy scanning a copy? pleeeeeeeze!

I'll PM those that ask...

 

[the_bird]

Orf, I just forwarded JB's PM with the link.

 

[John Beere]

Hey, congrats on the Zymurgy article! I just got my issue. I instantaneously recognized the pictures and the setup!!

Thanks - I was really pleased with how everything turned out... especially my logo.

 

[Orfy]

Well done on being published. Something for me to read later.

 

[Biermann]

Thanks - I was really pleased with how everything turned out... especially my logo.

Yeah, I love your DeepSix logo. If you ever come up with a tap handle, let me know.

 

[Orfy]

John, how about you doing this on the Wiki for us, or can we cut and paste it please.

 

[John Beere]

Its hard to believe, but the cooler has been operational for over a year now... holding strong at 36 degrees. The only problem I've run into is some of the adhesive holding the paneling on has come loose on the door - but thats hardly a problem.

The cooler has become a real bonus to our house... we can go to Sams Club and basically get anything we want - 'cause there is always room in the cooler. We also stage all our drinks out there and just bring em in as we need them.

I never gave a breakdown on cost - never really wanted to know exactly - but my best guestimate is around $1,400~$1,500 including all the storage racks used inside.

 

[EdWort]

Congrats John. Great job! Ya got a lot of jealous folks here, myself included.

 

[Jaybird]

I'll PM those that ask...

I will ask... that is really killer I would like to read it.
Cheers
JJ

 

[85 Haro Designs]

Well, as a newbie I just found this thread and read the ENTIRE thing. Very impressive work and just an awesome amount of information.

Just thought I would add my .02

 

[EdWort]

Bump. How's it still going. I'll be building a 4'x5' one of these in my BrewHaus soon.

 

[John Beere]

Hey Ed, the cooler is still running strong. FYI, I now run it at 34 degress (instead of 36) with a 2 degree diferential. It runs for about 5~10 mins ever 90 mins or so. We use it for all sorts of stuff and has become a great addition to our house. The only problem I’m having is a cosmetic one. The A/C has drawn all the moisture out of the glue I used to tack the plastic sheeting on the inside and it is coming loose in several places. I plan on turn it off for a day and using heavy double stick tape to tack it all back down.

FYI, I'm still around but life and work have taken precendence. Looks like things are settling back down for me though... hope to be more active soon.