Ethan Clarke
Waterproofing plastic containers is a useful skill with a variety of applications, from storing small items like medication and electronics to protecting larger items like camera gear and even entire submarines. While there are commercially available waterproof containers, like Pelican cases, that can be purchased, it is also possible to make your own waterproof containers using plastic bottles, resin, rubber seals, or other materials. In this discussion, we will explore various methods and materials that can be used to build a waterless box with a plastic container, taking into consideration factors such as cost, durability, and effectiveness.
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What You'll Learn
Use a plastic liner
If you're looking to build a waterless box with a plastic container, one option is to use a plastic liner. This method involves creating a waterproof barrier by lining the inside of the container with a layer of plastic. Here are the steps to follow:
Prepare the Plastic Liner
Start by measuring the dimensions of your plastic container, including the base and sides. You can use a roll of thick black plastic liner, similar to the ones used for backyard ponds. Ensure you get a heavy-gauge plastic that is durable and puncture-resistant. Cut the plastic to size, allowing for some overlap at the corners and edges.
Line the Container
Place the cut-out plastic liner inside the container, ensuring it fits snugly. You can use a staple gun to secure the plastic liner to the top edges of the container. Make sure there are no gaps or openings where water could potentially seep through.
Seal the Corners
The corners are a critical area to focus on. You can use a strong adhesive or waterproof tape to seal the corners of the plastic liner. This will prevent water from seeping through any potential gaps. Ensure that the adhesive or tape can withstand moisture and will not deteriorate over time.
Test and Refine
Once the plastic liner is in place, test the container by filling it with water. Observe any leaks or areas where water may escape. Make adjustments as needed, such as adding more staples or sealing certain areas with waterproof tape or adhesive.
Additional Tips
For added protection, you can apply a coating to the outside of the plastic container. Spar urethane, a type of spar varnish, is a cost-effective option that is intended for use in wet environments. Alternatively, you can explore using epoxy resin, glass fabric, or vinyl ester resin coatings, which are commonly used in boat-building to achieve permanent waterproof protection.
Remember, building a waterless box with a plastic liner requires some trial and error. Don't be afraid to make adjustments until you achieve the desired level of water resistance for your specific needs.
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Apply a coating
To make a waterless box with a plastic container, you can apply a coating to the container to make it waterproof. Here is a step-by-step guide on how to do this:
Prepare the Container
Start by selecting a sturdy plastic container with a tight-fitting lid. Ensure the container is clean and dry before beginning the coating process. You can use a plastic bin or upcycle plastic bottles or containers with lids, such as disposable water bottles or applesauce containers.
Sand and Smooth the Surface
If there are any rough edges or surfaces on the container, use sandpaper to smooth them out. This step will help create an even and smooth surface for the coating to adhere to. You can also sand down the area where you plan to cut the container (if modifications are needed) to ensure a smooth cut.
Cut and Modify the Container (Optional)
If you need a custom-sized container, you can cut and modify the plastic container to your desired shape and size. For example, cutting below the lid of a plastic bottle can create a larger opening and capacity. You can use a hacksaw or a sharp kitchen knife for this step.
Apply a Base Coat
Before applying the waterproof coating, you can apply a base coat to the container. This step is optional but can help fill in any minor imperfections and create a more even surface. You can use a thick bead of hot glue or super glue around the rim of the lid and any other areas that need smoothing.
Waterproof Coating Options
Now, you can choose a suitable waterproof coating for your container. Here are some options:
- Rubber Coating: You can use a spray-on rubber coating or Plasti Dip to create a flexible and waterproof layer. This method is commonly used for small-scale projects and provides an efficient barrier against water.
- Epoxy Resin: For a more permanent solution, you can use epoxy resin, similar to fiberglass resin. This option is pricier and may be more suitable for larger containers or boxes. It will create a lasting waterproof finish.
- Glass Fabric and Vinyl Ester Resin: For the ultimate waterproof seal, coat the inside of your container with glass fabric and vinyl ester resin. This method is used for building boats and will make your container permanently waterproof.
- Silicone: Silicone can also be used as a coating material. Look for silicone designed for doors and windows, as others may contain anti-mold agents that could be harmful to plants or other contents.
Finalize the Coating
Follow the specific instructions for your chosen coating material regarding curing or drying times. Ensure you work in a well-ventilated area and wear the appropriate protective gear, including gloves and a respirator, during the application process.
By following these steps and choosing the right coating for your needs, you can effectively apply a waterproof coating to your plastic container, creating a waterless box for storage or other purposes.
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Use seals and gaskets
When building a waterless box with a plastic container, seals and gaskets are essential components to ensure a durable and effective seal. Gaskets are crucial in preventing leaks and protecting the contents of the box from water damage. Here are some detailed instructions on how to use seals and gaskets effectively:
First, select the appropriate gasket material. Rubber gaskets are the most common and cost-effective option for creating a watertight seal. They are cheap, space-efficient, and highly effective due to their elasticity. When compressed between two connecting parts, rubber gaskets prevent liquids from entering the seal.
When choosing a rubber gasket, consider using O-rings, which are rubber rings with a round cross-section. O-rings have excellent suppression rates and provide superior protection against liquids. They are versatile and can be used in both static and dynamic seals. To install O-rings, create 2-3 grooves in the static part of the seal and place the O-rings within these grooves.
For larger-volume productions or a more streamlined assembly process, consider custom-molded rubber gaskets that combine all sealing elements into one piece. These custom gaskets simplify assembly and reduce the chances of misplaced seals. However, they might result in a bulkier appearance.
In addition to gaskets, you can also use seals made from other materials. For example, silicone seals are effective in creating a watertight barrier. You can thin polyester resin with acetone to achieve a milk-like viscosity and brush it onto the container's joints or seams. This creates a waterproof barrier that soaks into the wood, ensuring a durable seal.
When working with seals and gaskets, placement and compression are critical. Ensure that the gasket is correctly positioned without any faults or misalignments. Apply high compression at potential leakage points to maximize the seal's effectiveness.
By following these instructions and selecting the appropriate seals and gaskets, you can effectively create a waterless box with a plastic container, protecting its contents from moisture and water damage.
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Overmoulding
To build a waterless box with a plastic container using overmoulding, you can follow these steps:
First, select a suitable plastic container that is sturdy, leak-proof, and waterproof. This container will serve as the base component for your overmoulded seal. Ensure that the container is clean and dry before proceeding.
Next, gather the necessary tools and materials for overmoulding. This may include an overmoulding tool or injection moulding equipment, as well as specialized screws and sealing gaskets. The upfront investment in an overmoulding tool can be significant, but as Henry Ford pointed out, "the cost of not having the right tool can exceed the investment in the tool itself."
Now, you are ready to begin the overmoulding process. Cut the plastic container to the desired size and shape, ensuring that it will fit precisely within your final enclosure. Place a little dab of glue on the base of the container to secure it in place. You may also need to drill holes for the specialized screws, depending on your design.
Finally, apply the overmoulded seal to the plastic container. This process will involve injecting molten plastic or rubber around the base component, creating a strong and watertight bond. Allow the assembly to cool and cure before testing the integrity of the seal.
By choosing overmoulding for your waterless box, you are investing in the reliability and efficiency of your product. The upfront costs of the tools and processes may be steep, but the potential savings in field failures and customer relationships can rapidly offset these expenses, especially for products with a higher price point.
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Buy a pelican case
If you're looking for a waterless box with a plastic container, buying a Pelican case is a great option. Pelican cases are known for their durability and toughness, and they offer a wide range of products to suit your needs.
When buying a Pelican case, you'll want to consider the size, features, and specific use case. Here are some detailed instructions and considerations to help you choose the right Pelican case:
- Size: Pelican offers cases in various sizes, from personal micro cases to large cargo cases. Consider what items you'll be storing and choose a size that can accommodate them comfortably.
- Protection: Pelican cases are known for their ruggedness and protection. The Protector Case™ series, for example, is crushproof and made with military-grade materials. If you're looking to secure sensitive equipment like firearms, cameras, or electronics, the protection offered by Pelican cases is ideal.
- Water Resistance: Many Pelican cases are designed to be watertight and impact-resistant, making them perfect for extreme conditions. The Storm Case™ series, for instance, features advanced water resistance and a crushproof exterior.
- Mobility: Depending on your needs, you can choose Pelican cases with different mobility options. Some cases have quiet rolling stainless-steel bearing wheels, making them ideal for travel. Others have handles and in-line wheels, perfect for traversing rough terrain.
- Customization: Pelican offers various customizable features to organize and protect your gear. The Pick N Pluck foam interior solution allows you to customize the case to fit your equipment snugly. Additionally, features like zippered compartments and see-through mesh pockets help keep your accessories organized and protected.
- Security: If you're looking to secure firearms or other sensitive items, Pelican cases offer enhanced security features. Some cases have TSA key locks, while others have combination locks, ensuring your items remain safe.
- Weight: Pelican's Air Case series is designed to be lightweight without compromising durability. These cases are ideal for easy transport, especially if you're travelling with weight restrictions.
- Price: Pelican cases vary in price, with some options being more affordable than others. The Vault by Pelican™ series, for example, offers rugged and secure cases at a more affordable price point.
When buying a Pelican case, consider your specific requirements for size, protection, mobility, and price. By choosing a Pelican case that suits your needs, you can trust that your equipment will be well-protected and secure.
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Frequently asked questions
You can use a basic plastic bin and make it water-resistant by adding a rubber gasket or liquid nails gasket. You can also use weather stripping and put a bolt on each side to keep the latches from opening.
There are a few ways to make a plastic enclosure water-resistant, such as using seals and gaskets, overmolding, and welding. Seals and gaskets are the cheapest and most common method, while overmolding and welding are more suitable for mass production.
You can use a variety of materials to make a waterless box, including plastic, wood, silicone, glass fabric, vinyl ester resin, and metal. For plastic, you can recycle old bottles and containers by cutting them and gluing the pieces together.
You can make a wooden box water-resistant by coating it with epoxy resin, spar urethane, glass fabric, and vinyl ester resin, or silicone. These methods will create a waterproof finish, but they may not be suitable for plants as some silicones contain anti-mold agents.
Yes, there are pre-made waterless boxes available for purchase, such as the Pelican cases used to protect camera gear and laptops in wet environments. Alternatively, you can use a Rubbermaid tub to protect your appliances in the event of a flood.
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