Removing Built in Cooler

[duffymahoney]

Which model is it? My boat is getting the gel coat fixed and I think I want a new cooler. The built in one blows!

[ajholt7]

http://store.tige.com/products/48-qu...sulated-cooler

[dingleberry]

http://store.tige.com/products/48-qu...sulated-cooler

Is that the exact same model as the 48-qt one on the AO site? (obviously without the Tige logo) http://www.aocoolers.com/index.cfm?f...6&ParentCat=22

If so - yikes! Slight price differential

I have the non-Tige version, and it does rock

[ajholt7]

Is that the exact same model as the 48-qt one on the AO site? (obviously without the Tige logo) http://www.aocoolers.com/index.cfm?f...6&ParentCat=22

If so - yikes! Slight price differential

I have the non-Tige version, and it does rock

I would think so.

[da.bell]

What is everyone doing for cooler space then?

Filling it with beer. You can never have enough beer, right?

Okay, we put our dry foods in it.

[wallacmc]

I have been thinking the same thing, especially since we all surf goofy.

[Booms]

Cut out the cooler yeasterday. I am amazed at how much space I am going to gain. That cooler was a waste of space. I will take some pictures tonight and post them tomorrow.
Now I am looking for carpet. Anyone know where I can find the grey carpet that is used? Is it marine specific or something I can order online?

[Iwndr]

If you cannot find it some owners have used Rhino Lining or similar products

[chpthril]

Cut out the cooler yeasterday. I am amazed at how much space I am going to gain. That cooler was a waste of space. I will take some pictures tonight and post them tomorrow.
Now I am looking for carpet. Anyone know where I can find the grey carpet that is used? Is it marine specific or something I can order online?

how much you need, i have in stock.

[Dave S]

Can you post some pics of the open area? I assume it would be a mirror image of the other side. We don't use our cooler either. I was thinking of removing it for more storage. I am a goofy surfer as well.

[Booms]

how much you need, i have in stock.

PM sent

[Booms]

Can you post some pics of the open area? I assume it would be a mirror image of the other side. We don't use our cooler either. I was thinking of removing it for more storage. I am a goofy surfer as well.

Dave S - I will take pictures tonight and post.

[Booms]

I have everything ready to install the carpet. I just need the carpet - Thank you Chpthril for supplying.

I tried many different ways to get the cooler out. The first three were trying to save the cooler -
1. Short prybar - I used a wide putty knife between prybar and fiberglass so I would not cause any damage when prying. This did not work. The glue/epoxy used is too strong.
2. Stand in cooler - Did not work. Standing in it only caused the bottom to crack open. Here again the glue/epoxy is too strong.
3. Rotozip - Cut the glue out. Space between the cooler and fiberglass is too tight. I did not have a good angle from inside the cooler or inside the storage area.
4. Rotozip - Cut out the cooler from inside the cooler. This started out ok then all three of my bits broke.

5. Full size Sawzall - This got the cooler out. I used a 4.5" all purpose blade. I wanted to use a short blade so I did not damage the fiberglass from the inside. I had to hold the large Sawzall on an angle to cut out cooler. It was too big to fit in cooler. One thing with a full size Sawzall the cooling fan on it blew the fiberglass dust everywhere. If you have a third hand have it hold a vacuum to suck up the debris. If not be ready to wipe down everything in boat. After cooler was out I still had about 4-5" of cooler side to cut. I remember seeing the smaller size Hackzall by Milwaukee tool so I went and purchased one. This 12 volt saw is awesome. I was able to cut the left over edge to just .5 - 1". If you do not have this little Hackzall I recommend one. For its size, it is a beast. After I cut out the remainder of the cooler I sanded the edge smooth with 320 grit sand paper.

The cooler was approximately 22"x14"x10" so I am picking up just under 2 ft3 from the cooler and probably 3 to 4 ft3 in total extra space. Let's say I am picking up 3.5 ft3. That is about 26 gallons of water that I did not have in my surf sac. So I am adding approximately 218 pounds of water to the darkside!

Looking forward to having the custom surf sac fill up the entire starboard side storage area. All of the darkside riders (myself included) are sporting a semi right now looking forward to this long weekend. May the Force be with you!
Pictures below.

[wallacmc]

That semi you were referrign to is correct. However, it is more than tempered by the thought of using a reciprocating saw on that blind with other fiberglass behind. That takes kahones and skills I'm not sure I have. Nice job, though. It certainly is intriguing.

[Booms]

wallacmc - Trust me I checked where the blade would hit the fiberglass. Only two areas were of concern, the area with the cup holders (lower right hand corner of the first pic) and the side right behind the captians chair. Instead of holding the Hackzall's guide plate flush to the cooler I angled it so approximately only .5" of the blade was used. A couple of times the angle was too extreme and the blade would not cut so I just decreased the angle and had the blade cut deeper. If I did not feel compfortable doing that I was going to make a spacer using wood. However, that little Hackzall is so light and easy to control I did not have an issue.

I will be in the Nati in three weeks. If I had more time I would be more than happy to help. I will be there only one night for work but we will be visiting my favorite locations - Tellers in Hyde Park for their famous Buffalo Chicken Eggrolls and then Nada in downtown for a little mexican fair.

Go for it. You can do it!