If you cut the handles off I would seal with silicone or epoxy ..Awesome build and definitely one to put on my list. After reading the comments, would it be too much of a hassle to saw off and then grind down the top cooler's handles (to avoid the temptation of trying to lift with those)? I know I would remember to lift using the bottom...but my inebriated friends might go for the path of least resistance.
Or maybe rig up a slight shock strip for when someone goes to lift it using those?
Ive had no problems yet lifting mine from the bottom handles, no flexing or warping of the plastic anyway,If you cut the handles off I would seal with silicone or epoxy ..
I had considered running a length of small cable with ring connectors crimped on, between two short heavy sheet metal screwed into the sloped area of the upper and lower handle where it blends into the body on both sides to transfer the load.
Maybe a good idea, hadn’t thought about my friends grabbing it while drunk.
Hmm, 40# beer and 40# ice and 10# cooler etc / 4= 22-23# per cable
Some testing is in order, maybe use 2 anchor screws per side to distribute the load.
I’ll get back to u.
One down, one to go. I decided to flip where the gas and beer lines mount for a different look. Some of the cuts are a little rough but overall I'm happy with how it turned out. Thanks for the guide.Good luck building them! Post a pic when your done.
I just measured with a ball lock corny keg inside. There is 2 3/4 inches left over from the top of the corny keg to the top of the cooler edge. The cooler top that screws on is slightly recessed in the middle of the cover, so you may gain a little room there as well. Hope this helps.....Resurrecting this old beast. Has anybody tried using a commercial sixtel in one of these with a sanky on top? How much head space did you leave for the corny?