Reinforced Wheeled Cooler

Everything was going great with the cooler until the day I decided to use it; the handle broke on the very first day of camping.

Scrap metal pieces (1" and 1 1/4" sections, 5/8" round stock), M16x80 bolts for the axle, 6013 welding rod and flux, 3/16" bolts for the arms, 7" rubber wheels, and a lot of patience.

When taking measurements of the cooler, the original openings and the wheel-axle channel were taken into account so as not to drill into or modify any of the cooler's plastic

Create the base

To construct the axle, it was reinforced with 1" x 1/8" flat bar to provide rigidity and the necessary height for the 7" wheels.

It was decided to use foldable arms rather than expandable ones, which also saves space for transport.

Final step: it was coated with truck bed liner—a water-based paint that is highly durable and resistant to outdoor conditions and rough treatment.