Carbon Fiber Draft Beer Dispensing Stereo Cooler

For those who have ever floated down a river on a inner tube and dreamed of draft beer & good tunes.  


Carbon Fiber-Draft Beer Dispensing-Stereo Cooler

Beverage Capacity: 2.0 Gallons

Stereo Play Time:  6+ Hours @ moderate volume

Electronics: (4) Infinity 6.5" marine speakers, Dual Marine MCP100 USB, SD (60 watts x 4 channels), Deep Cycle Battery (23 amp hr)

Note: Wheels are removed.


About this instructable:  It was never my intention to post a detailed step by step construction guide, rather a general over-view of construction and lessons learned.  I hope to see another like it on the river some day :)

Outer shell constructed of 2X Owens Corning Foamular 3/4 in. (r-4) Tongue and Groove Insulating Sheathing.  3-M 77 Spray Adhesive and sheet rock screws used to hold pieces together until carbon fiber is applied..

Dividing wall (1.5 in.) and backing for wheel well added.

Styrofoam block inserted to fill dead space and provide level base for battery.

Note: I added 3/8"  wood spacer between styrofoam insert and outer walls.  logic being that it would give long term support for axle well.  It is the only wood utilized and most likely was not necessary.

Added outside wall for electronics compartment.

After sealing joints, cracks, and holes, a simple primer coat was added.  Thinking it was a good idea, I added dry wall corner molding to help give more rounded effect. 

Note: This step was not required.  I later added top cap which I carefully routered and shaped by hand.  In short, end results looked great but added allot of extra time to the project.

After sanding and floating corners, an additional 1.5 in. of r-4 board was added to accommodate the (4) 6.5" marine speakers. 

Note: Cut a wire channel between layers for speaker wire from cooler side and any additional wiring. (external switches, battery indicator, solar wiring, etc..)  Adding rigid tubing between layers would be helpful for future expansion and wire replacement. 

Once again float, sand, prime.

Apply Carbon Fiber

After trimming and sanding, a top base was added.

Note to self:  Measure keg height prior to constructiuon.

Carbon Fiber applied to top cap.

Another layer of carbon fiber.

After sanding and trimming, a layer of resin was generously applied.

Note: Retaining the carbon fiber look was never my intention, rather I wanted a smooth white finish. The extra cost of resin was applied to fill low spots. 

Satisfied that all voids and cracks were addressed, everything was once again sanded smooth.

 Afterwards, cut outs were made for stereo head unit, 12v socket adapter (for charging battery), and (2) compartment drains.

Decided to add a recessed beer spigot.

Note: As mentioned earlier, moving the spigot up an inch or two would have given needed clearence.

Constructed and primed compartment doors.

Cooler side (shown): Layer of 3/16 plexiglass and two recessed layers of 3/4" r-4 board

Electronics side: Layer of 3/16 plexiglass and one recessed layer of 3/4" r-4 board

First layer of carbon fiber on compartment doors. After resin cured, excess was trimmed, sanded, and second over-lapping layer of carbon fiber applied.

Tires: 8" Non-Marring Rubber Tire
http://www.harborfreight.com/8-inch-non-marring-rubber-tire-47638.html

Axle: 5/8" SS tubing (local scrap yard) captured with on each side w/ removable pin. Simple 1/4" thick rubber wear gaskets inserted between tire and cooler as wear gaurd.

Axle Well: (forgot to take pic) 3/4" schedule 80 pvc.  Sealed inside and out.

Couple coats of marine paint.

Couple coats of marine paint.

Couple coats of marine paint.

Mount speakers and run wiring. 

12v cigarette lighter socket installed.

Note: 1/2" thick gasket was added to each speacker to provide adequate clearance.   Yep... measure twice, cut once.

View of installed speakers and 12v cigarette lighter socket.

Install compartment doors and hindges. 

Install beer spigot and compartment door latches.

Add vent covers to electronics compartment door.

Electronics

Dual USB SD (60 watts x 4 channel) Stereo
http://www.dualav.com/marineaudio/mcp100.php

23 amp hr. deep cycle battery (Academy)
Note: Will replace this with a gel battery some time in the future.

Note: Electronics compartment was originally designed to house larger battery, small cooling fan, and 4-channel marine amplifier.  After some consideration, I decided that portability (25+ pounds lighter) was more desirable that hair splitting volume.  Given such, wheels could have been further recessed to allow proper clearance.

2 Gallon Stainless Keg (eBay)
12oz Paintball CO2 Bottle (Academy)
Regulator (eBay)

Ready for ice.

Wheels added.

Handles- Attwood® Stern Handles 2-Pack
http://www.academy.com/webapp/wcs/stores/servlet/Product_10151_10051_12527_-1?Ntt=handles&Ntk=All

Electronics Compartment Drain Plug:
http://www.academy.com/webapp/wcs/stores/servlet/Product_10151_10051_12440_-1?Ntt=drain+plug&Ntk=All

Dual USB SD (60 watts x 4 channel) Stereo
http://www.dualav.com/marineaudio/mcp100.php

Resting on sandbar after third successful trip.