Insulating a Styrofoam cooler is a simple yet effective way to extend the life of your cold items, whether you’re packing for a picnic, a camping trip, or just need to keep your drinks chilled at home. By following a few key steps and utilizing the right materials, you can transform a basic Styrofoam cooler into a highly efficient insulated container that will keep your contents cold for hours on end. In this comprehensive guide, we’ll walk you through the process, providing detailed instructions and technical specifications to ensure your DIY insulation project is a success.
Measure the Cooler
The first step in insulating your Styrofoam cooler is to accurately measure the interior dimensions. Using a tape measure, record the length, width, and height of the inside of the cooler. These measurements will be crucial in determining the size of the insulation materials you’ll need to cut and fit.
Cut the Insulation
Once you have the cooler’s dimensions, it’s time to select and cut the insulation. Reflective bubble insulation is an excellent choice for this project, as it offers an R-value of 1 to 1.5 per inch of thickness, providing effective thermal resistance. Using a ruler and a Sharpie marker, transfer the measurements to the insulation and then carefully cut the pieces to size using a sharp pair of scissors.
Fold the Insulation
With the insulation pieces cut to fit, the next step is to fold them into a box shape that will snugly fit inside the Styrofoam cooler. To reduce bulk on the sides, you can opt to cut the side “box” flaps in half. This will create a more streamlined fit and minimize any gaps between the insulation and the cooler walls.
Tape the Insulation
To secure the insulation in place and create a cohesive box shape, use aluminum foil tape to seal the seams. Aluminum foil tape is an ideal choice as it has a temperature resistance range of -40°F to 200°F (-40°C to 93°C) and a tensile strength of 35 pounds per inch of width, ensuring a durable and long-lasting bond. Avoid using duct tape, as it can be susceptible to mold and mildew if exposed to moisture.
Place the Insulation
With the insulated box now assembled, it’s time to place it inside the Styrofoam cooler. Ensure a snug fit by carefully lowering the box into the cooler, taking care to align the edges and corners. When packing your food and drinks, be sure to cover the top of the contents with the top flap of the insulated box. You can even add a few extra inches to the measurements to create a small flap that can be tucked into the inside of the cooler for added security and insulation.
Insulate the Lid
To further enhance the insulation of your Styrofoam cooler, you can also insulate the hollow lid. Start by drilling a few holes in the sides of the cooler’s lid, making them large enough to accommodate the straw nozzle of a can of spray foam insulation. Use these holes to fill the inside of the hollow lid with expanding foam insulation. Allow the spray foam to harden for 24 hours, and then remove any excess that has expanded out of the holes.
The spray foam insulation used for this step typically has a compressive strength of 10 to 50 pounds per square inch and an R-value of 3.6 to 6.5 per inch of thickness, depending on the specific type of foam used. This additional layer of insulation in the lid will help to further retain the cold temperature inside the cooler.
By following these steps and utilizing the right materials, you can transform a basic Styrofoam cooler into a highly efficient insulated container that will keep your contents cold for hours on end. Remember to always measure accurately, cut the insulation precisely, and use the appropriate tapes and sealants to ensure a secure and long-lasting insulation solution.