ICELESS BEER BOX

Abstract

Here I present the Iceless Beer Box, an overly complex and undeniably superfluous solution to a minor problem. The importance of the coldness of beer has been well documented. The Internet community has witnessed prior attempts to tackle the lightly-pressing issue of quickly chilling beer below 0°C. Significant advances over previous work include the capacity to chill several bottles simultaneously and construction from widely available components. 

This project was completed in 2005.

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Materials

• beer (bottled)
  
• vodka (cheapest possible)
  
• igloo
  
• air conditioner
  
• fountain pump (submersible)
  
• copper tubing (~30')
  
• electronic thermostat (ranco)
  
• cpvc pipe & fittings 

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Tools

• the basics (drill, saw, screw drivers, etc)
  
• pipe tools (hammer, bender, cutter etc)
  
• refrigeration tools/supplies (freon, acetelene torch, solder, pressure gauges, fittings, etc)
  
• spare wire, twist connecters

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igloo preparation

1. removed wheels and handles
   
2. started bending copper tubing to fit igloo
   
3. continued in zig-zag pattern
   
4. replicated steps 2 & 3 for return
   
5. soldered together with 3rd short u-turn
   
6. drilled holes to allow exit of tubing, pump power cord, and temperature probe 
   
7. cut and assembled rectangular shape of cpvc pipe for coolant circulation
   

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a/C Preparation

1. opened a/c unit
   
2. captured freon for recycling
   
3. cut tube just before it enters the evaporator and just after it exits condenser
4. added tube to route evaporator entry to condenser exit
5. routed tube from igloo to entry of compressor and added valve. added filter & valve to exit of condenser
6. routed high pressure (thin) copper tube from filter to remaining end of igloo tube (insulated with wet paper towel to prevent igloo from melting)
   
7. pressurized with freon
   
8. checked pressure after several hours - held steady at ~75psi. (it probably wasn't necessary to route the evaporator and condenser in series - just one condenser would have been enough)

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electronics

1. disconnected built-in a/c thermostat
   
2. drilled hole to mount new thermostat
   
3. routed temperature probe inside spare copper tube up into igloo (required additional hole)
   
4. using spare wire, connected thermostat to a/c power control
   
5. spliced in pump power cord (see thick black cable) for continuous running
   
6. summary: routed wires through a/c on-off switch; any on position turns on the thermostat, which in turn controls the compressor. pump is always cycling.
   

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odds & Ends

1. packed everything in
   
2. cut out sections of a/c cover
   
3. capped valves
   
4. added L brackets to sides of cover, drilled screws into bottom of igloo (meant for stabilization — it's possible to pick up the unit carefully from the igloo, but it's better to carry it from the bottom of the a/c)
5. added silicone to holes in igloo
   
6. secured cpvc fixture with screw zip ties
   
7. cut and placed wire mesh in bottom (direct contact between beers and copper tubing causes freezing)
   

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operation

1. filled reservoir with 3 large bottles Crown Russe coolant
   
2. added beer
   
3. turned on
   
4. set thermostat to 27°F (~-3°C) with 4°F (~2°C) differential
   
5. waited a little while
   
6. enjoyed several cold beers

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