The boxes are handmade moulded fibreglass products, with a high density polyurethane core giving the box its excellent insulating qualities.
The moulds are polished repeatedly by hand before a releasing agent is applied to the mould. The mould is then gel coated before the laminating takes place. Once the lamination is complete and allowed to cure enough, the moulds are then bolted together then the foam is poured in. The foam expands rapidly causing a very high density filling. The box is then left to cure in the mould for a period of time before it is removed. Once removed it is checked and trimmed of any flashing on the edges.
It is then sealed on the seam and each box is individually polished before stickers, handles, hinges and latches are fitted. Each lid is adjusted and trimmed to fit the box before a final inspection is done and then packed.
The same process applies to the making of the fibreglass lids.
The fisherman lids are cut from HDPE plastic on a jig and then fitted with the appropriate EVA foam which creates the seal between the box and the lid.
The boxes range from a 4litre to an 85litre.