Rustic Hardwood Cooler

Coolers tend to be rather unoriginal, but yours doesn’t have to be; it can be as unique and intriguing as you are. All you have to do is build one with wood! It really is quite simple and it will have all your guests asking what high-end store you bought it from. This tutorial will give you everything you need to know on how to build a cooler that stands out.

Materials List

• 5: 2x2 @ 8 feet long
• 1: 1x4 @ 8 feet long
• Old cooler (You can buy new or choose to line your cooler with insulated foam. There are also very affordable Styrofoam coolers that could work for this project)
• 2 1/2 inch screws
• 2 inch nails
• 3/4 inch pipe coupling
• 3/4 inch spigot
• Handles

Step 1: Disassemble Your Cooler.

You’ll want to take off all the hardware on your cooler. Make sure it is stripped down and the lid is fully detached.

Step 2: Measure Your Cooler and Build the Sides

Measure the width, height and depth of your cooler, and determine the height you want it to be. If you want it about counter height, the legs should be 30 inches. Make sure you account for your 2x2s when you do your measurements. When placing the bottom support, add 1.5 inches to the distance between the two, because you’ll be adding 2×2 supports for the cooler to sit on. So, if your cooler is 15 inches tall, place the lower support at 16.5 inches below the top. Build two sides.

Step 3: Connect the Sides to Finish the Frame

Once you have your two large sides built, cut 4 2×2′s at your depth measurement and attach with wood glue and 2 inch screws. Measure the distance your supports need to be for the cooler to sit on. Cut two and attach with glue and screws.

Step 4: Insert the Cooler

Place your cooler into your frame. It should fit snugly without compressing the sides.

Step 5: Cut Siding and Attach with Nails

Now that your frame is built, you can measure how long you want your slats to be. Start on each end and work toward the center, nailing down your slats with 2 inch galvanized nails. Add some glue if you want additional stability. Once you get to the center, measure the gap and cut a piece to fit. Nail slats down on both long sides, and your non-draining end.

Step 6: Cut Drain Hole and Attach Siding to Last End

We used a 1 1/2 inch spade bit to make a hole in the center of one slat. We decided to start in the center on this end, because it didn’t seem wise to try and cut a uniform hole in the middle of two separate boards. Once your hole is cut (and you can use a jigsaw or router if you don’t have a spade bit or hole saw attachment) nail it down to your frame. Attach the remaining slats.

Step 7: Add Trim to Top and Edges

You need to add trim to the very top of the cooler, to hide the rim where the cooler meets the wood. Cut your pieces down to roughly 2 inches wide with a table or circular saw. We chose to do 45 degree angles, but you can keep things simple with a 90 degree, if you like. Once you’re done trimming the top lip, add trim to the top and bottom, to the sides, and any decorative pieces.

Step 8: Create Lid Frame

Here’s where that 1×4 finally comes in. Measure your cooler lid, and create a box around it with the 1×4. Attach with nails and glue or screws. Place the lid onto your cooler, making sure that it fits snugly. It should pop out a little lower than your frame. With the lid still in place, screw the frame into the lid so it’s secure.

Step 9: Cover Lid and Add Trim

Measure the top of your frame, and cut your wood to fit. Nail it down into the frame. Next, measure how tall the distance is between the trim on your base to the top of your lid, and trim down your boards as required. Measure the length to cover the box, and nail into your lid frame. Add trim to the top and/or sides if you’d like.

Step 10: Cover the Legs

Measure from the bottom of your legs to the bottom of your boards. In my case, it was 15 inches. From here, I cut down a few fence slats at 15 inches tall, and then ran them through my table saw to create the leg facings. On two sides, the pieces were 1.5 inches wide, and on the other two, they were 2.25 inches wide to account for the thickness of the wood. I just nailed them straight into the 2×2 legs. Add a little glue if you got some.

Step 11: Attach Hinges

Attach to your lid first, then line it up with your base and make sure the lid fits snugly. Once fit, attach the hinges to the base of the cooler. The hinges attach on the inside and outside. It flips open with ease!

Your cooler is now complete! All that is left to do is host a party to show off your newest project! And don’t forget to check out our other how-to tutorials for even more one-of-a-kind DIY projects! Enjoy!