18v Cooler A/C

I saw an IcyBreeze at a swim meet in the brutal Texas heat last summer and wanted it immediately but was shocked at the sticker price. I converted a cooler I had and sourced some components after seeing it in action. It doesn't have all of the features, but works great. I will update the run time on the batteries after a couple test runs.

This isn't the only one on the internet or even Instructables, but is in my opinion the most simplistic taking 30-45 minutes to complete.

Donor Cooler, Mine was a 40qt Igloo Cooler from Academy

18V Makita compatible fan (Aliexpress)

Lee Valley Expandable Hose 2-1/2 (1 Piece to be cut in half)

5-3/4" Hole Saw

2-3/4" Hole Saw

6-32 2" stainless machine screws (6)

6-32 stainless acorn nuts (6)

6-32 stainless washers (6)

black silicone

5/32" drill bit

Phillips Screwdriver

Deburring tool

The lid pops off easily when open and is held in by two plastic nubs. The 2-3/4" hole saw fit perfectly in the drink holders molded into the top. The base of these is angled at the bottom side at the cup holder. For the larger hole saw, choose a place approximately 3-1/2" from the indent on the hinge side edge. This will leave roughly 1/4" lip after the fan is installed.

In between the two layers of plastic is expanded foam. Debur the inside and outside edges as needed and seal the foam with silicone.

One of the vacuum hoses (Item 03J6062) from Lee Valley is roughly 1 meter long. Cut this in half remembering there is a wire inside. Feeding the hose through the holes is a very tight fit. I found working from the inside through to the top was the best approach and expanding it after it begins to squeeze through makes it easier to maneuver. After installation, seal both the top and bottom with the black silicone to stop water from entering into the foam.

You will only need a Phillips screwdriver to disassemble the fan. There are six screws, but the light will also have to be disconnected. I originally planned to add a pump to recirculate the water or install the fan face/light inside the cooler, but don't see any reason for the added complexity now. I removed the handle, but that isn't necessary for the project.

Afterwards, center the fan over the hole and make and drill the six holes all the way through. Attach with the screws and washers/nuts on the inside.

This should be completely the same setup for DeWalt, Milwaukee, etc. as long as you can find a fan or battery converter for the batteries you currently have. This isn't as advanced as the IcyBreeze, which has a heat exchanger and can plug into your car...but that unit runs $289, and has proprietary 12v batteries. This uses the battery system I currently have and cost less than $110 all in (excluding batteries).