Rough Sawn Wood Patio Cooler

By Robert Robillard on Remodeling, Weekend warrior

Cut the side material

With the cooler upside down on my work bench and my bottom frame on top of the cooler I then measured the height of the wood sides.

Important Note: Deduct the thickness of the wood you are using from this side material measurement. This is important because you will later be covering the upper frame with this wood. If you don’t, your lid will not align and close correctly. I neglected to do this and had to add rough sawn spaces to the lower frame stretchers to make up for this error.

I ripped the rough sawn down to 6” wide boards and then added a bevel to the cut ends for decorative reasons. To add the bevel you can use a bock plane and do it manually or set up a router and a bevel bit.

Note: throughout this project I tried to hide or eliminate cut edges when I could. Areas that could not be avoided ended up being on the top lid and I’ll describe how I dealt with that later in the article.

Attach the Side boards

I attached the 6” side boards to the upper and lower frames using DAP DynaGrip Wood-Panel-Trim adhesive and 2” galvanized finish nails. I used a pneumatic nailer.

Note: The DAP DynaGrip Wood-Panel-Trim can be used for bonding all trim materials including wood, foam and PVC. It is a latex formula that wipes off and washes off your hands later fairly easy. The new DynaGrip adhesives were designed to deliver high-strength bonds in hours, not days, and to provide exceptional performance even in the most extreme weather conditions.

When installing the boards I spaced them evenly on the front face and left any filler gaps at the corners. Depending on how large or small the end corner gaps were I filled them with scrap boards or left them. This area is getting covered by the legs in the next step and will be hidden.

Note: the bottom is left open to drain and allow air to dry the back sides of the frame and side panels.

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About the author

Robert Robillard

Carpenter / Remodeler / Editor

Rob Robillard is “The Concord Carpenter” Rob is a builder, general contractor, carpenter, woodworker, and editor of Concord Carpenter and ToolBoxBuzz As a General Contractor and carpenter, Rob owns and operates Concord Carpenter LLC. A full-service remodeling and construction company. Rob is a recognized leader in home building best practices and a source for how-to information for building professionals. On this website, Rob covers all aspects of home construction, building science, home improvement, woodworking, remodeling, and some of the best product and tool reviews. Rob is in charge of our Tool and Product Review series - Concord Carpenter Videos where we post all of our tool reviews and video tutorials. Rob approaches remodeling and building construction with a pragmatic and problem-solving approach. He enjoys using his knowledge and experience to help and educate building professionals as well as DIYers on best practices in the construction and remodeling industry. He's a strong advocate for "raising the bar" in the construction trades and promoting the trades to youth. #BeAMentor #Green2Great Craftsmanship, quality, and pride guide his journey on this channel The Concord Carpenter's motto: "Well done is better than well said!" : Read more about Rob

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