For those super hot summer days, the floor vent is not enough at times. When it is over 95 degrees outside, the floor vent will keep the van temp at about 86 degrees. However, this cooler mod + the floor vent working together will get the van temps down to about 80.

There are awesome swamp coolers built for vehicles, but the only ones that will work better than this setup run at about $450+ each. Furthermore, they ALL require you to use ice, not bottles. This setup will run you under $100, but more importantly, it will allow you to use frozen bottles, rather then ice. Personally, I use this setup because I am too lazy to wake up an extra 15 minutes earlier to make time to buy ice at the store prior to starting surveillance.

We will start this project with a 28 quart Coleman cooler. I chose this size as it will hold six 2 liter soda bottles tight. So the bottles don’t fall over during pursuit.

We will also be using two USB server cooling fans. I used: Thermaltake Mobile Fan II External USB Cooling Fan from Amazon for $10 each.



Step One: I used a small screw driver to remove the metal stands from the USB fans.

Step Two: I used a dremel to cut a square hole for a tight fit for the USB fan.

Step 3: Cut out a small section for the USB controller and apply black gorilla tape and some super glue (to help hold the tape) to the cutout for a cleaner look.



Step 4: Install the USB fan with the controller on the outside face of the cooler. Using clear silicone (I used Lexel), apply around the USB fan so it remains permanently installed.  *** The fan that goes to this upper hole must blow air INTO the cooler. Please test it and place the fan correctly.



Step 5: On the other side of the cooler, use the same steps but place the controller towards the bottom of the cooler. ***Make sure this controller blows air OUT of the cooler.

Step 6: I purchased a cheap USB 3.0 hub and used silicone to glue it to the cooler. I connected both fans to the hub so when I am in the van, I only need to connect one USB instead of two. I also siliconed all the fan wires to the cooler so they don’t get in my way.



The below is optional but will work MUCH better if you have a floor vent. (See my other post for floor vent installation)

Step 7:  I purchased a 5 inch rubber coupling, and using black Gorilla Tape and clear silicone, I installed the coupling around the exhaust fan.



Step 8: I purchased a 4 Inch flexible PVC hose that easily inserts into the rubber coupling. This will allow you to direct the cool air to any direction you need without moving the cooler in your vehicle.



Step 9: Buy six 2 liter soda bottles and use them to freeze your water. I just leave them in the freezer at all times until I need to put them into the cooler. I also use a one liter bottle solely for the purpose of making a very tight fit for all the bottles so they don’t move around during surveillance.



And your done!

If you have the floor vent, the best way to use this setup is to put the PVC hose directly above the floor vent fan. This way the fan will blow cooler air into your vehicle. If you do not have the floor vent, just direct the PVC hose to the area that needs the most cooling.

Please note: This is not a standalone solution to cool your vehicle. This is an addition to a floor vent or other cooling method. I don’t use this unit everyday, as my floor vent is enough. I only use it on 90+ degree days.