Introduction
Discover how to craft a versatile, battery-powered air conditioning system that operates independently of the grid. This innovative DIY project combines common materials such as a sturdy cooler, a high-efficiency radiator, a pond pump, and other accessible components. Designed to deliver up to 10 hours of cool, refreshing air using ice packs, this system is perfect for camping, outdoor events, or emergency off-grid cooling needs.
The core principle involves using a radiator to transfer heat away from the air, which is then circulated by a fan powered by batteries. Water is pumped through the radiator, absorbing heat from the surrounding air, and the cooled air is expelled into the environment. Insulation within the cooler ensures the temperature remains stable, maximizing cooling efficiency and duration.
Materials Needed
- Insulated Cooler: A large, well-insulated cooler such as the Coleman Xtreme, capable of retaining cold for extended periods.
- Radiator: An automotive transmission oil cooler, chosen for its high heat exchange capacity.
- Fan: A 18-volt battery-powered fan, for example, the Ryobi hybrid fan, to circulate air effectively.
- Pond Pump: A USB-powered pond pump with an open intake, suitable for continuous water circulation.
- PVC Pipes and Fittings: 4-inch diameter PVC pipe and a long sweep elbow for directing water flow.
- Toilet Flange: A 4-inch flange to connect the PVC pipe securely to the cooler lid.
- Insulation Foam Board: 1.5-inch thick foam panels, cut precisely to fit within the cooler’s interior.
- Metal Components: Aluminum angles to create a stable stand for the radiator, secured with zip screws.
- Other Supplies: Zip screws, a small piece of scrap wood for elevation, silicone sealant for waterproofing, hot glue for temporary holds, USB power bank to energize the pump, compatible batteries for the fan, and optional salt for enhanced cooling.
Constructing the Cooler
Begin by positioning the toilet flange centrally on the cooler lid, ensuring it’s clear of hinges or latches. Mark the outline for cutting. Drill pilot holes along the marked circle, then carefully use a jigsaw to cut out the opening, creating a precise hole for the PVC pipe. Repeat this process on the opposite side for the fan opening. These modifications will facilitate efficient airflow and water circulation.
Setting Up the Radiator
Measure the internal dimensions of the cooler to determine the ideal length for the aluminum angles. Cut the angles to form a rectangular stand that raises the radiator above the cooler’s bottom, promoting optimal water flow. Secure the stand inside the cooler with zip screws, ensuring stability and level placement. Attach the radiator to the stand, screwing it into the cooler’s sides with zip screws and sealing around the edges with silicone sealant to prevent leaks and mold formation. This setup allows for easy removal and filling with ice.
Creating the Insulated Chamber
Use the radiator’s packaging as a template to cut a foam board that fits snugly around the cooler’s interior, forming a dedicated ice chamber. Additional foam pieces can be added on the sides for extra insulation. Cut the foam in half for easy access, enabling quick filling and re-sealing of the ice compartment. Cover exposed foam edges with HVAC tape to prevent styrofoam particles from contaminating the water or clogging the pump. Attach the radiator’s inlet and outlet tubes to the sidewall openings using HVAC tape, ensuring airtight seals for efficient heat transfer.
Testing the System
Fill the insulated chamber with a gallon of water and three bags of ice, making sure the pump’s intake remains submerged. Power the pond pump using a USB power bank and verify water circulation through the radiator. Turn on the fan and observe the airflow and temperature of the air exiting the outlet pipe. Make adjustments as needed to optimize performance.
Final Assembly and Operation
Securely attach the fan to the cooler lid and connect the outlet pipe to the toilet flange. Fill the ice chamber with additional ice and water, adding salt if a faster cooling effect is desired. Connect the pond pump to the USB power source and the fan to its respective batteries. Once operational, this setup provides a portable, efficient cooling solution suitable for off-grid environments, outdoor activities, or emergency situations.
Image Credits: Make Everything
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