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Good question.
The bases may be slightly different but I can assure you there is not much difference between the older 86 qt and the 94 quart coolers other than the lid being 2 inches taller.
Here are the facts as I personally know them.
I owned both the 86 and the 94 qt coolers at the same time.
I set them side by side and also measured them. Almost identical...
I then took both lids off and put them on the opposite coolers. The lids fit exactly as I even used the hinge screws to mount the other lids on. The hinge screws fit perfectly on the other cooler. The only difference in the lid was the 94 was 2 inches taller and had 2 latches in front instead of the one on the 86 qt cooler.
So, no other difference in the lid as the hinges were even in the exact same place.
Tom Clark may be able to elaborate more on this subject as he designed the 94 qt cooler cleat. There may be slight angle changes and maybe 1/16 inch difference in the base but I sure couldn't measure it.
Plastic molds are not even exactly the same from cooler to cooler.. Plastic expands and contracts in temperature just like many other materials...
For me, the coolers are about as exact as you can get except for the 2 inch taller lid of the 94 qt....
The interior mold of the 94 Igloo Marine quart cooler is identical to the interior mold of the old 86 Igloo Marine quart cooler but the EXTERIOR mold of the 94 quart Igloo Marine cooler is slightly different and slightly broader at the base than the 86 quart Igloo Marine cooler.
The difference in breadth is about 1/2".
The lid of the 94 quart Igloo Marine cooler is completely different and about one inch taller, hence the greater capacity.