marine ply/glass over. Worked well. Got about a 1/2 a day out of the ice before it all melted. I probably could have sealed it around the lid a bit better for better performance.Really heavy in weight though!!!Funnily enough, I am in the same situation and need to make another 1. Just weighing up options and what the best way will be this time without spending a motza on it.. If anyone has some surfboard foam they don't need I would be interested..

Yeah, I hear there is a foam that can be used and works well! looking at making a 700-1000L job with a smaller divider for bait

 We made some at tafe years ago out of coolroom panel, big enough to hold a few cartons in along with ice. Would of kept ice for near on a week i reckon. But sorry dude no pics

i think it would be cheaper to buy one...  one of the site sponsors here does eskies.  but if you really want to make one, source some foam that they use to make foam sandwich fiberglass yachts out of.  comes in various thicknesses.  you can cut it to size with a hand saw, stick it together with expoxy resign and q cells (rounding the internal corners).  Easy to sand, and fiberglass inside and out.....   or just go and buy one...  

 A urethane type of foam is what you need. Glueing aluminium foil on it prior to classing will add even more ice holding capacity. The ply is really only reserved for the lid to add strength.

I can get photos if you like.

Get a small chest freeze that is dead. Pull the motor out, makes them way lighter. Then just put a big boat bung in the bottom. Ice lasts for days, keeping stuff frozen is what they are designed for. Can pick them up for free, only cost is one bung.

i made one out of ply, fridge panel, and fibreglassed it all up

took me days and in the end I regretted wasting soo much time on it

have bought a couple of Mac eskys off Dave from extreme. Very helpful and holds ice for days

 I saw a good one on another site will go and pick foam up tomorrow should be good fun! May put marine ply on base as well incase someone tried to break ice bags in there. Thanks for te aluminium foil idea! Would buy one but then it wouldn't be what I want

 Foam core and fibreglassed. Easy to build, any shape, but these days quite expensive. But if your after a custom shape and willing to put in the hours you will get a great esky. If you want some pics of my last one pm me your email. i have the full step by step process and can give some good advice in relation to problems i have encounted. 

Tony

as the boys above have said , cheapest and easiest is either an old freezer, with motor removed , or to make out of coolroom or freezer panel

they both work well for extended periods with block ice , especially if you can keep the lid shut as much as possible

we used to get up to 3 days easy when we put 20kg solid blocks of ice into them , even in the summer if kept under shade

hezzy

however wont fit in the space I have.

Where can I buy some urethane foam from??South west area if possible??

 I found some in Welshpool or are you looking further south?

 Just thought I should add something. Contact cement to glue the urethane pieces together is all you need. Simple and cheap as the glass does all the bonding. The main reason with these types of eskies with loss of ice quickly will be the lid seal. Get it right with the right rubber and the ice will last a very long time. Invest in good clips to help with the seal. The ones dad has made of late even have these clips recessed so they don't catch like factory ones can. I'll try and get some happy snaps.