My DIY Cooler Project

[RP62]

Just finished my DIY cooler project and since I took a little different route than many I've seen, thought I'd post some pics. This is my first time posting pics, so be gentle (this in fact is a test pic to see if I can figure out how to post).

-RP

Looks like the caption on the pic isn't very readable. What it says is that I started with a carbonator I got off the my local CL for $50.

[Zmechanic]

I basically went the same route you did. I re-used the tank and reset the pressure relief on the pump to 40 PSI. I did take the back-flow preventer off the pump, though. You got a much better deal on the carbonator than I did though, Haha.

Good luck with it!

[charger891]

nice set up! wish i could of found a pump like that when i built mine.

[acourtjester]

HI RP62
Her is how I modified my tank for the cooler.
And I added a fan blade to the other end of the motor.

have fun
Tom

[RP62]

Finally getting around to actually posting the rest of the pics. First of all the enclosure. As noted, the carbonator dimensions ultimately determined the height and width (12" high by 13.75" wide). I should mention that I don't have a brake and I suck at bending sheet metal with any precision and since I started this before the torch came in, I went with what I know - machined fittings and riveted construction.

-RP

Started with some .080 aluminum plate since I've got a big piece in the scrap pile.


Cut some 3/4" X 1/8" angle


Riveted the angle to the bottom plate.


Machined some corner fittings


Attached the corner fittings to the bottom plate


Attached the angle aluminum to the corner fittings


The corner fittings worked out real well.

[RP62]

Next Installment. Finishing the bottom and making the front and back panels. After this I machined the water fittings. I'll post those tomorrow.
-RP

[RP62]

Next, the fittings. These are the ones I had to make because they either aren't made or I couldn't find what I wanted.
-RP

[RP62]

The last fitting is for the filler neck.

[RP62]

Next the heat exchanger.

[RP62]

Now, the fun part - final assembly. I figure all total, I've got less than $200 in parts and materials and about $1000 in my labor LOL, but it was an interesting project. I did a lot of research on this before I started and never saw this particular way of doing it so I thought I'd post my pics. I've got the output pressure adjusted at 50 psi. The probe on my kitchen thermometer goes through the inlet fitting and lays along side of the hose going to the cooler. I wrapped it with an insulating tape so that it should give a fairly close reading on the fitting/hose temp.
-RP

[Jake98]

Nice job! You folks that know how to do this stuff amaze me!

[sportbike]

I just received a fairly large Dyna Flux cooler for cooling a motor controller and motor for a machine I designed at work. I think your's may be put together better than the dynaflux.

[jakeru]

Really nice work. I like the gauges, and the green paint is a nice touch. I'd like to see how it looks all hooked up to your TIG machine, once you've gotten it hooked up and all done. Very impressive machining work, also, and attention to detail. How did you cut the slots, holes, and shapes in that panel?

I don't have a lathe or mill. So if I had to make fittings like that, I'd probably try to find existing fittings that have at least one threaded end or connection that I needed, saw them off, put them together and TIG weld them. I have taken two brass fittings, hacksawed desired endpieces off them, and TIG welded them together before. The brass doesn't TIG weld that cleanly (from the zinc boiling), but it is possible to make it quite solid, and even look great if you sand/polish the weld afterward, you can make the weld "disappear". It is a good way of making "custom" fittings I think, when suitable donors fittings are available.

Tom (acourtjester): I love the way that you formed that aluminum shroud around your fan. What tool and technique did you use to do that?

[acourtjester]

The process is called hammer forming you use wood for a pattern and form the metal to it's shape.
The attached images are of a magazine pages of how its done. If you cannot read it email me and I can send them to you.
I have used it many time to make different sheet metal things.

[blasphemy000]

Wow...I like both those coolers. Great job guys!