WIP - Rolling Cooler Speaker Box

I'm back with another DIY project!  You may remember my waterproof MP3 speaker system: http://www.teamfortress2fort.com/forums/t/WIPWaterproofMP3PlayerSpeakerSystem-21541.aspx?p=1

Well, it worked amazingly for what I needed, but now I need something... "more."

So I decided to build a full blown stereo system inside of a full-sized rolling cooler.  It will feature 4 speakers, a dash-mount car stereo, and an iPod interface.

So here are the basic plans...

I will take this cooler:


and will mount these speakers (one on the left and right side):


along with these speakers (both on the front):


powered by this stereo:


I already have the speakers and stereo lined up with sellers on craigslist.  The 2 pairs of speakers will cost $50 and the CD Receiver will cost $50.  To power all of this, I will be using 2 12v batteries (same model I used for the waterproof speaker) inline.  I already have one, so I will only need to buy 1 more for $20.  The cooler runs $30.  I will also buy an iPod interface adapter for the stereo to control the music and everything the iPod does via the head unit for $10.  For the basic build, I should expect to spend around $160.

As for the plans of the build, here is a quick diagram of how I shall approach it:



The blue box is the head unit mounted vertically to a carpeted board of wood.  This board will then be affixed inside of the cooler so that the lid protects the head unit in case of bad weather or when not in use.  The red shapes are the round front speakers that will be mounted one on top of the other.  The green shape represents the oval speakers that will be mounted one on each side of the cooler.  The yellow boxes are the batteries which will be attached to the bottom of the cooler.  This will not be a functional cooler at all.  It's purpose is 100% to provide music.  Additional design decisions include adding a custom iPod dock with the iPod interface adapter next to the head unit and adding a power switch and charging port on the mounting board as well.

I will keep this thread updated with my progress and photos.

I picked up the cooler tonight.  It will work perfectly.  I got it for free (practically) because I had to return a radio at Walmart for the exact same price.  That brings down the price to $130.

Also, the cooler has a water drain spot on the bottom backside.  I shall modify this to house the charging port so you can charge without having the lid open or ajar.

You mean as a hole for the plug to come out of or replace it with a place to plug in a cord?  If that is the case then can the batteries handle being hooked right up to AC current without a converter?

The batteries will be connected to a dc power jack:



When you pop off the drain cap on the bottom, you will see this inside of it.  You can then connect a standard battery charging pack to it and plug it in to AC.



This is what I did with my waterproof speaker.

I picked up the DC charging jack and it could not fit more perfectly into the water drain.  It's as if the manufacturers wanted it to happen.

Another addition I'd like to make is a power antenna.  It could mount on the back next to the handle so that it blends in better.  However, that may be something I add later down the road considering I can get FM radio via my Zune... but it would be nice to get the hockey and baseball games on AM.

I picked up a pair of Pioneer 6.5" speakers for use on the front of the cooler.  I got them for $27 clearance and they sound pretty darn good!

This thread needs more pictures. Also:

Pictures will come... for now, not much is in.  I'm waiting on my 5x7 Kenwood speakers to come in.  I also just won a JVC head unit from Ebay, so hopefully that will come in this week.

When I do have all of it, I will immediately begin cutting out the holes and mounting everything.  That is when I'll be posting more pictures.  But for now, here is what I have purchased:







Also, I think I'm going to just paint the mounting board instead of carpeting it.  I would like to also paint the blue shell of the cooler.

I started working on the construction of the head unit mount.  Cut out of a 1/4" plywood board:

I used a simple jig saw to cutout the diameter of the inside of the cooler.


Here you can see the two batteries on the bottom of the cooler.  (One of these was approximately half the entire size of my waterproof speaker.)

Here's the cooler with the board sitting on top the shelf ridge.


Don't worry about the gap going around the edge... there will be piping on the edges of the mount to finish it off.  Also, I will include brushed nickel handles on either side of the head unit to make it easy to lift up when needed.

A buddy from work custom builds his own speakers and speaker boxes.  He has a lot of scrap sound dampening material, so I will try and scrounge up enough to cover all the sides on the inside.

Very nice.  What did you use to round the edges so precisely?