Step 10: Rout the Lid Rails and Slats for the Lid

Photo: Kolin Smith
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Set a rail on your work surface, place a scrap board directly behind it, and clamp a third board over the first two to act as a router guide, as shown. Put a ¾-inch straight bit in your router. Set it to inch and make multiple passes, lowering the bit each time until the rabbet is inch deep. Rout the other rail. Clamp the four lid slats edge to edge, and clamp these slats and a router guide to your work surface. Rout matching rabbets inch deep on both ends of the slats.
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    Tools List

    • 30-foot tape measure
      Tape measure
    • miter saw
      Miter saw
    • bar clamps
      Long and short bar clamps
    • drill
      Drill/driver
    • 1/8-inch bit with combination countersink
      -inch combination countersink bit
    • straight edge
      Straightedge
    • circular saw
      Circular saw
    • router
      Router with a ¾-inch straight bit
    • multi-bit screwdriver
      Screwdriver
    • 1/8-inch twist bit
      -inch twist bit
    • spade bit
      1-inch Forstner (or spade) bit
    • adjustable wrench
      two adjustable wrenches

    Shopping List

    1×4 cedar Get eleven 10-footers.

    Igloo Ice Blue MaxCold 50 cooler with threaded drain plug. Go to igloo-store.com

    1½-, 1¼-, and 2-inch deck screws

    -inch brass or stainless-steel screws for the lid slats

    ½-inch brass spigot

    ½-by-3-inch brass nipple

    ½-inch brass double female connector

    29-inch brass or stainless-steel continuous hinge

    Brass or stainless-steel gate handle

    24-inch brass or stainless-steel sash chain

    Wall-mount bottle opener

    Teflon tape

    Double-sided foam tape