Need a solution for the annual beach trip. Normally I load up the kegerator and haul it and the kegs several hundred miles. Getting too old to do that now. This was a perfect compromise. I picked up an old 10gal Home Depot cooler at the flea market for $5. It was faded and beat up, as well as waterlogged.
Made the initial cut just above the drain valve with a handsaw thru the outer skin and down till it just touched the inner liner. Did not cut thru. Removed the valve and used a large flat blade screwdriver to gently separate the bottom complete with foam. This left just the liner, mark the bottom of the liner just at the tangent of the sidewall curve and cut out the center with a utility knife to clear the keg and ice.
Bought a new 10gal cooler from Home Depot ($50 ouch) and removed the new lid so that the old cooler liner can slide down into the new cooler. This works because when they blow old the liner there is a slight taper to help with removal from the mold.
Next step was to cut the center out of the old cooler lid the same diameter as the old liner. Take your time and use a sharp utility knife with heavy gloves. The liner should slide down thru the lid. Do not cut away the flat area just inside the threads that seals against the top lip of the cooler. Finally use a can of foam that sets hard, not the water-based eco friendly stuff, and carefully fill the hollow area in the old lid all around. The foam will expand out, just let it dry then cut it off flush. Slip the old cooler body thru the lid down to the insulation, then insert the liner into the new cooler and screw the old lid onto the new unaltered cooler. Align the handles and silicone the old lid to the bottom of the cut insulation of the old cooler.
Now you have a 5 gal keg cooler that easily converts back into a 10 gal water cooler just by unscrewing the top section and swapping lids.
I hate painting, but wanted this cooler to look nice, so off to Home Depot for a short roll of reflectix and some tape.
Done, hope all this made sense. Will let you know how the cooler holds up at the beach.
Many thanks to the OP and all the follow ups!
Photos to follow..
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Cheers
Jbrown57
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