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Engel Cooler Backrest

Old 01-18-2015, 12:22 PM
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Default Engel Cooler Backrest

In between and during large projects, I take on lots of much smaller projects. This past week I was contacted by a local fly fishing guide who wanted to add a backrest to his Engel 80 Quart cooler. He has the cooler mounted in the center of his Banshee and is practically the only seat on the boat. The backrest will definitely make his customers more comfortable and will also give him a grab hold when running the tiller motor. Check it out:

First, I got started with the custom rod holders which will hold the backrest and allow the backrest to be easily removed:

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With the rod holders mounted, I made the backrest support bar:

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Old 01-18-2015, 12:31 PM
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With the rod holders installed and the backrest support bar fabricated, I got started on the actual backrest:

I used expanded PVC foam board for the mounting board. This board will never rot and holds a staple well.

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I then cut out a nice shape to match the bottom cushion profile:

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To strengthen the PVC board, I added a length of stainless steel tubing which I bolted to the PVC board:

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Next, I drilled the backrest bar and added 1/4-20 stainless tee nuts to the PVC board:

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The four holes in the center are for the future addition of a back mounted shelf or box to hold a wallet or drink:

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Old 01-18-2015, 12:34 PM
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Next, I got started on the foam and upholstery. First I had to modify the foam to accommodate for the stainless steel cross bar:

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Old 01-18-2015, 12:40 PM
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Next, I made the vinyl cover in the same style as the bottom cushion:

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I first glued some sew foam to the plain white vinyl. The sew foam is an extra step but it makes for a better looking cushion:

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I then pre-stitched some pre-made welt to the facing:

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Next, I added the boxing. At the bottom of the cushion, I stitched in a mesh material to allow any water to run right through the DRIFAST foam:

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Finally, I stapled it all to the foam board:

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Old 01-18-2015, 12:46 PM
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And, here is the completed project:

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And here is the cooler assembly installed on the Ranger Banshee:

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Thanks for looking!

Raymond
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Old 01-18-2015, 12:58 PM
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Another great project Raymond!!
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Old 01-18-2015, 12:59 PM
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Very nice!
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Old 01-18-2015, 02:52 PM
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Superb welding! Nice shop too.
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Old 01-18-2015, 03:12 PM
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How much would something like this cost? Been looking to do something similar behind my leaning post on my bay boat. Cost for rod holders and back rest with cushion.
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Old 01-18-2015, 03:36 PM
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Nice work I have had a similar idea, with just a grab rail. My worry is how the cooler will handle the stress.
Is this the first one you have done, if not any problems with it cracking the cooler side?
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Old 01-18-2015, 04:48 PM
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Really nice job....looks like there is a lot of attention to detail
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Old 01-18-2015, 05:36 PM
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Dang Raymond, you couldn't do no better than that? Just kidding of course Beautiful work as always, my friend

There are only 2 people that I trust to do work on my boats, that's me and Raymond. If I can't do it, he can
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Old 01-19-2015, 03:26 AM
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Beautiful Work Sir!
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Old 01-19-2015, 06:03 AM
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Nice project
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Old 01-19-2015, 06:07 AM
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Thanks for all of the nice comments! As for whether the cooler will handle the stresses, I do not think there will be any issues. The wall thicknesses of both the inner liner and outer cooler are close to a 1/4 inch thick. Plus, by using a larger backing plate on the inside, the stress is spread out over a large area. I didn't see any flex on the cooler when I sat and pressed against the backrest.

Skirt Chaser, send me an email to info@martinmarinedesign.com with pictures of your leaning post and I will be happy to quote you a price for LP backrest.

Take care, Raymond
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Old 01-19-2015, 06:25 AM
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You do nice work Ray. Continued success!! Your brackest to raise the cooler off the deck are the best!!
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Old 01-20-2015, 07:42 AM
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Looks great raymond. Kai and I were testing it the other day. Glad I brought him to you.
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Old 01-20-2015, 02:14 PM
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Thank you Kirk! I certainly appreciate and am very grateful for you recommending me for the job! I look forward to working with you again in the future.

Take care, Raymond
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Old 01-20-2015, 09:11 PM
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Looking perfect, what wealth of talent.
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Old 01-21-2015, 04:44 AM
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Is the cooler a bit of a bitch to open with the handles right there at the rod holders? I know some coolers like to get a bit of suction when the hot and cold air meet as the lid closes.
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