Malting rig build!

[J Dot]

Hello again Guys,
Since we are bringing the rig back!
I cleaned her up a bit, found my original sketches ,
Replaced the traction strips, etc.

Anyhow
If any of you wanna follow me on the rig ( malting ) procedure,
Basically the same as before, BUT instead of malting In a bowl,
It goes into tumbler, until ready to dry! This will be a learning
experience for me as well! Learning to use it correctly!

So
If any of you wish to BUILD A RIG , I’ll supply some pics, parts list,
Dimensions, etc!
If you might want to tackle the build?
I’ll start with my sketches , and the bucket first,
Then I’ll post again , more about the machine!
As we go along!

J Dot
{:0)

The pics:
( as you might see I did a few mods from the sketches, like the cork rings
Around the screens on the bucket ( for ONLY a cleaner look ) not needed
As well as the traction strips, etc )
Feel free to put your own twist on it, or go oak, whatever, just have fun!

[J Dot]

Here is a parts list

2x4 pine 96” long ( 8 feet )
1x2 pine 72” long ( 6 feet )
4x furniture feet ( the hammer in kind ) usually a 4 pack
4x 2 inch plastic casters with mounts ( 4 screw kind )
2x. 3 inch ( soft rubber ) casters ( make sure you can take the
caster off of the mount, and also that it has a PLASTIC hub,
as we need to drill it out to fit the rottisery shaft )
Rottisery accessory for BBQ grill
Timer ( heavy duty ) with 48 pins ( 30 minute intervals )
( or digital )
SCREWS
WOOD SCREWS
1) 2 1/2 inch long ( small box )
2) 1 1/2 inch long ( small box )
3) 3/4 inch long ( small box ) at least 12
5 gallon bucket with sealable lid
Small piece of screen ( enough to cut 2 5-1/2” circles )
Hot glue or adhesive of some kind ( non toxic )
( optional ) CORK gasket maker ( for donut holes )
Some kind of rubberized adhesive strips for around bucket
( I had this roll from an auto a/c repair )

Misc:
Different drill bits to PREDRILL holes, for screws ( 1/4” works well )
Also a COUNTERSINK bit if you want the screw heads flush ( looks better )
Impact driver will help with those screws, but good ole screwdriver will do
If you want pop-eye arms!
Electric drill or cordless to predrill holes, can also work as screwdriver
But lots of bit swapping! Also a jigsaw or something to cut holes into bucket.

I might tear mine apart to show the pieces and steps!

DEPENDING on the parts you buy,
Yours may be a bit different from mine, as you parts might be longer or shorter,
Skinnier, wider???????? Who knows, so you’ll need to tweak it along the way !
But we will get it!

I’ll post more tomorrow!

J Dot

More pics

[hellbilly007]

That's a cool build. Thanks for sharing. This is almost the same as what I have planned, other than I want to use either a 30 or 55 gallon drum. Hoping to do 50 lb batches at a time.

This past weekend I picked up a rotisserie motor that's never been used, along with a bunch of electronic odds and ends, $5 bargain box.

[J Dot]

That's a cool build. Thanks for sharing. This is almost the same as what I have planned, other than I want to use either a 30 or 55 gallon drum. Hoping to do 50 lb batches at a time.

This past weekend I picked up a rotisserie motor that's never been used, along with a bunch of electronic odds and ends, $5 bargain box.

Thank you,
50lbs is a LOT, Brother, wow.
But on the other hand, do it once, and be supplied for a while! Lol

As for the rotisserie being able to handle that, I dont think it will!
Mine with the 5 gallon bucket, with 10lbs soaked corn ( nearly 20lbs wet )
Or close to it, would bog down on the up stroke, to the point it would start
Smelling BURNT, I knew I was pushing it too hard, so I REDUCED THE BAFFLES,
From 1”x 2”, to 1”x1”, this helped, but you might need to gear it down, but
Then it will spin too slowly! If you are going that large, I’d use a 110v motor,
Belt or chain drive, with gear reducing pulleys or sprockets. You might have better
Luck? Will still run on the timer, just attatched a cord whip to 110 outlet!

As for the deal on the goodies and rotisserie , WOW, that does not happen everyday!
Good show!

This rig caught me off guard with a SLEW of problems, along the way!
Unforeseen issues!
First TRACTION, the drive wheels would slip on the smooth bucket
Solution
1) sand the bucket to a rough finish ( failed! ) but was better than smooth
2) ducttape ( worked for a bit then failed, wheels burnt through the tape )
3) weather stripping ( wheels burnt through with 1x2 baffles, but not with 1x1 )

Next was baffles, as explained above,
Then ( multi directional motor on rottisery unit ) each power cycle would turn the motor
OPPOSITE directions, causing the shaft to come unscrewed ( the shaft is composed of several smaller
Pieces ( of different length ) as it is universal fit )

Then drive wheels slipping on shaft, you name it, but after a few tweaks
I think I got it!
Please keep these things in mind, as you assemble your rig! But MAN
would I love to see her go! 50lbs! Wheeeew you are brave!

( I would also like to share a side note, my own discovery so to say )
I found 16 hours to soak is a good number, also when malting, if you turn the corn with
Your hands your hands should be a bit SLIMY, not wet, not dry, but slimy feel!
Keep this moisture throughout, until your corn is almost finished ( 1 day and a half ) cut back on the water
Just enough to not let the corn dry out ( watch the roots ) they will discolor or schrivel
Too little water, never over water, spray bottles work great!
And look into ( peroxide ) In your soaking water, might help with your large batch?
Was referred to me on a 10lb batch gone bad! Worth a look!
But GOOD LUCK!
Would love to know how it goes!

J Dot
{:0)

[J Dot]

Hello
Jerry here, sorry went away for a 4 day weekend ( family gathering ).

Ok,
Getting back to the rig!
I disassembled my rig, to walk you through the build!

The first thing we want to build is the SQUARE frame,
We will add to it later, when fitting the rotisserie and
Bucket casters and stops!

For now we need:

2 pieces of 2”x4” pine cut to 20 inches long
And
2 pieces of 2”x4” pine cut to 15 inches long

This will be our basic frame!

Ok the 2 SHORTER boards, we need to pre drill a few holes!
Both will be the same,
So on each board , measure ( 3/4” ) from EACH END, draw a line ( this is our guide line )
Use a speed square if needed.
Now on the line you just drew, measure ( 1-1/8” ) in from each side!
This will leave you with 2 center points on each end of each board!
These are our pilot hole points.
We want to drill the points out with a ( 1/4” ) drill bit, then COUNTERSINK the pilot
Holes a little bit! ( see pics below )
( you can hold boards together to predrill both boards at one time
If all went well you should have 8 centered holes ( 4 each board )
Now we need our ( 2-1/2” screws ) to assemble the parts!
I numbered my boards ( see pics ) as I had to take mine apart, and
Wanted to put it back the same!
Now screw the borders together to make the frame!
KEEP IT SQUARE ( 90^ angles ) , NOT parallelogram and
Caddywompus! Lol

Ok
Now we should have our basic frame!
See pics

J Dot
{:0)

The pics:
Don’t worry about holes, marks, etc, we just want the basic frame for now,
We will cover those things later!

[J Dot]

Hello,
I wanted to add, for those of you following my post,
The first part was cut, and added to the ( GRAINS )
Forum, under “ MALTING CORN “!

So this one could continue with the Rig build,
And use! Hopefully we get lucky! Keeping fingers crossed!

I will post more tomorrow evening when I have more time,
So we can get our rigs further along!

Good evening!
J Dot
{;0)

[J Dot]

Ok
Let’s move onto the next step!

Mounting the rotisserie and soft rubber casters!

First we must open your rotisserie kit, find the
( MOTOR & mount, the shaft tail mount, and a combination
Of shaft pieces to be slightly longer than our basic frame!
MUST: be long enough to enter motor housing, and protrude
Through frame to tail mount!

Ok,
Now we need to measure the diameter of the shaft?
( each might be different mine is ( 14mm or close to 9/16” )
We will need this measurement to
A) drill our casters
B) drill our basic frame!

I went 9/16” on my casters, and 5/8” on my frame!

Ok,
You can drill out casters, but the frame shaft needs to be
OFF CENTER, I went 1/2” , But can go more, this puts the weight
Of the bucket on the shaft, and not the guide casters!
See pic below, I went 8” from one side ( leaves 7 on the other )

( you’ll have to figure this out as your kit might be different?

But you want to center the first hole where you want it,
Then match the opposite side, then mark and mount the
Motor mount and tail mount
( TAKE NOTE TO CENTER SHAFT IN HOLES, do not let shaft rub anything but
the motor and mounts ( see pics )
Then place on motor, slide on drilled casters ( this is a PAIN ) do not glue them yet!
Place shafts in and screw them together, should look similar to last pic, next post!
( only 6 pics per post, so I will post twice, with all 12 pics:
We are using only 1-1/2” screws, also I had to alter my mounts, drilled
Out the screw holes, as mine had none! So you might have to tweak it a bit?

J Dot

Pics:

[J Dot]

More pics from post above:

J Dot

Pics:

[J Dot]

After
You complete the step above, it’s a great time to
TEST HER OUT!


Here is a video below

I’ll post more tomorrow on bucket placement and
Guide caster , and furniture feet placement!

J Dot
{:0)

Video below
https://youtu.be/1DxVmXvkigM

[J Dot]

Hello

Ok
The final part!
( but also the hardest! )

First we will need

2x 1”x2” pine cut to 15”
2x 2”x4” pine cut to 13” ( was scrap cut in half )
Furniture feet
4 3” casters
1-1/2” screws
2-1/2” screws

First we need to prepare our ( 2x 1x2 pine ( 15” ))

First
Measure in 3/4” from each end, square a guide mark,
Then measure across 3/4” from side edge make the ( + )
For our 4 pilot holes, drill the x’s out with a 1/4” pilot drill bit.
And then countersink the holes.
( both boards are the same so far )

Next
We need to prepare the 2x 2x4 pine ( 13” ) ,
Measure in from ends ( 2” ) , square a guide mark,
Measure from side edge 1-3/4” mark your ( + ),
Drill our +’s, and countersink.
( both boards the same so far )

Use pics below as reference

Ok
On our basic frame,
Measure in 3” ( FROM MOTOR SIDE ) mark, predrill , and mount your first
1x2x15” board ( 1-1/2” screws )( don’t worry bout ( the furniture feet yet ) mine were already
Mounted, I had no choice without tearing them up removing them!

Ok this is where it gets HARD, and will take a bit of finagling to get right,
Hold bucket where it looks good, then
Mount 2 of the casters ( 1-1/2” screws ) on the side with the LARGEST GAP, between shaft and frame!
( remember we offset shaft to one side )
Try to get the bucket SQUARE, centered on shaft how you want, and to where bucket will stay
Put.
Like pic below

( WARNING: do NOT place casters IN LINE with the buckets BAFFLE SCREWS )
This will cause bucket to stop spinningor fall out of cradle!

Ok
Now we need to mark for the ( furniture feet ) mark the 2 spots where the bucket crosses the 1x2
( see pics )
Drill and install 2 feet ( center of board ( 3/8” ))
With 2 feet and 2 casters installed,
Now take bucket off, you’ll see we need to mount our 2x 2x4x13” boards ( see pic )
( using 2-1/2”screws here )
To mount other side of caster, after 2x4’s are in , go ahead and place last 4 screws in casters
To complete that side!

Now we want to install the other 1x2x15” board
( 1-1/2” screws )
First we need to mark the 2 bucket crossing spots, and install feet, then install all the 1x2
Not too tight, leave a small gap ( 1/16-1/8” )
( these are only to keep bucket from wondering around )
See pic )

Now last 2 casters ( again, just barely touching ) as not to lift bucket off of drive wheels!
Like pic below ) ( 1-1/2” screws )
( I only mounted one side of each caster on this side, you can add another SCAB, to mount
Other sides, but not needed )
Now replace bucket, should fight snug but with a tiny bit of play, and not move
around very much!
If all is good, plug her in and give her a go!
( VIDEO BELOW )

And done!
Good job! We now have a malting rig! Add the timer , and bam! Automated!

J Dot
( good luck on your build )
Will malt corn real soon in it, and you can follow my journey here!

Video:
https://youtu.be/WoNTHFfByOU

Pics:
( last 6 pics in next post! )

[J Dot]

Here are the last 6 pics

J Dot


Pictures:

[J Dot]

Ok
Give me a few days, and I’ll run some malt!
I use ( organic POPCORN SEED ) works well!
If you built a rig , and want to follow along, order
You some organic popcorn! Non gmo, kind!
I have white baby, yellow baby, calico ( multi colored ),
Glass gem ( spectrum of colors ) , as well as a few others!
I most likely, will run some YELLOW BABY, as I’m out of yellow malt!
2-5lbs worth, not sure yet!

But good luck on your build ( if you decided to )
And if you just want to learn to malt corn,
Follow me here, beginning to end!

Take care
J Dot!
{:0)

Pics:

[J Dot]

Hello, Everyone,
Just checking in, and as luck would have it,
Celebrating my 46th Today! Woo hoo!
As my bday is 7-27-72! Yes 7 is my lucky number
So let me be the first to raise a toast! TO YOU GUYS!
“ To the Smartest, most ingenious , funny, and just Brilliant,
New friends! Here is to you! “

CHEERS!

If I survive the party, and can function tomorrow, I might get
To doing something! Run malt in this darn rig! If not, the bucket might
Make a nice helmet? Doh!

Hope your week treated you well, and the weekend goes smoothly!

Have a great evening, I’ll be back tomorrow evening ( July 28 2018 ),

We will get to soaking our corn! ( step 1 ).

J Dot
{:0)

[googe]

Awesome tutorial mate!. very detailed. You done did a good job

[Manc]

Happy birthday J.dot sorry it's a bit
late as we're in the future here in the UK. Hope you had a great party

Lee

[J Dot]

Hello,
Well I survived ( barely ) !
My wife decided to go through my phone,
And invite ALL my friends ( contacts )!
WOW,
Did not realize, exactly how many friends I have!
Over 300 people here!
I was expecting a FEW friends, not the entire city!
Luckily all my neighbors are EXTREMELY COOL!
( and let us use their yards to park cars in!
I’m on 1 acre of land, and did not have the room!

Everything went without a hitch!
Props, to my wife, niece, nephew, and brother!
For cooking, preparing and well EVERYTHING!
50 people is big, this was an EVENT!
( we also hired a lifeguard for the pool, as I was
Worried with SO many people and SMALL children,
It was the safest thing to do! )

It worked,
Everyone went home SAFELY!

GOOGE:
Thank you! I appreciate it! Truely means a LOT to me!

MANC:
Always a pleasure hearing from you!
Late, Ha,
You are “ ON TIME, like ROLEX! “
THANK YOU, and yes, I believe this was the BEST
Party ( bday ) I EVER had!
But will say, feeling my age afterwords! Whew!
Cannot hang with these young bucks!
They trying to kill me! Lol

Well spent yesterday CLEANING,
ALL DAY!
Then it hit me! Too old for this stuff!
Lol

But tonight I will start the next run of malt, through
The tumbler, this time, still feeling a bit “ SLOTH LIKE “
Today, but I’ll snap back!

Looking forward to seeing you tonight!
Hope you are all WELL, and the weather has been kind,
And your weekend is/was great!

J Dot

[The Baker]

Glad you had such a great day, and may you enjoy many more.

Geoff

[J Dot]

Hello Everybody!
Ok as promised,
Time to malt, in this part we will be pre soaking our corn,
Simply cover corn with water ( I use Distilled ) .
I posted pics below:

Ok,
We will need:
1) your pop corn ( I’ll be doing APPROX 4Lbs )
2) large enough bowl, to hold corn, and allow a couple
Inches of water to cover it ( corn will swell up )
3) enough water to cover corn in bowl ( I use distilled )
( see pic below )

Ok,
Simply put corn in bowl, cover with water a couple inches,
Then sink any floaters, and stir corn to release any trapped air bubbles!
( see pic )

Then set aside for ( 16 hours ) untouched
( NOTE: if for some reason the corn swells out of the water ,
Just add more water ( keep all kernels submerged )

That’s it!
Pics below!


J Dot
{:0)

Pics:

[J Dot]

While we wait,
I wanted to share a couple things ( life hack stuff ).

First
I’d like to talk about jar LIDS!
Not sure if it is just me? Or if any of you have the same issues?
Anyhow
I seem to always run into the problem of finding a clean lid,
( no writing on it ) as I mark everything, but when I reuse, and need
To make new marks, some lids are so marked up, I get confused!
I use permanent markers, and have tried different colors, lol,
My point
If you use ( white out or similar product )
You can use a paper towel, or fingernail, to simply scratch or
Wipe it clean! And left with a clean new looking lid! Just wanted to share!
Might save you from buying new so often.....
( see pics below )

Next,
Bamboo toothpicks make great drip guides!
( see pics below )

Also
I found my wife had these 100% cotton pads for removing her makeup
And they were perfect size for my little strainer I use on collection jar!
They are perfect!
See pics !

And lastly
Just wanted to share, a fix I came up with,
With my rig, as temp starts to level off and run,
It spits and sputters a bit out collection tube ,
Ultimately pushing my drip guide ( toothpick ) out,
Sometimes causing a mess, as it spills away from collection
Jar and all over my table! Eventually pans out, but a pain
Non the less!
So I took a small stainless measuring spoon, bent it, and hung it
From the side of the condenser pot, and it works BEAUTIFULLY!
( sorry wanted to brag a bit! Lol )
See pics!

Ok
Off to bed, see you all tomorrow!
Have a great evening!
J Dot

Pics:

[J Dot]

Continuation

Pics:

[The Baker]

Remove marker writing with....alcohol.
Foreshots...
Stubborn writing, with a steel-wool-pad-with-soap; and...alcohol.

Take the level in a very small barrel with a skewer, bamboo (best) or stainless.

Geoff

[J Dot]

Thank you Geoff,
( my problem was between ( stripping and spirit runs )
Found the whiteout to be VERY SIMPLE ) you cannot
Get really clean fine lines with it, but for numbering
Jars, it’s perfect the ole’ 4 lines with the angle through for
The # 5 gimmick ) not sure the numbering system?
Not Roman although that would work!
I love the little life hack stuff, or anything
That is simple, but effective! I will take that over
Any new fangled digitized, contraption, ANY DAY!
Lol

I just figured if you really wanna learn, you have to start
Back at square one, then upgrade as you go along!
For several reasons
But mostly $
Start cheap, then if you don’t like it, or whatever,
Than you loose nothing! Just saying!
I tried the ( Deflegmator ) only cooled my rig too much,
The gin sack, even, double boiler ( which is a Complete PAIN )
To find myself back at my original 3 pot ( store bought ) rig!
Which almost Sealed my fate, last night!
Keen sense of smell savithed me!

My worm stopped? WTH, so I pumped the heat, figuring maybe
The propane was low, or the fan being on cooled it? But temp was
On point around 178-180 by this time, still nothing? So I went full blast
And turned on thumper heater, ( I’m not sure any of you, PREHEAT, your thumpers?
I do with a hot plate ( saves time )) finally I started to get a drip, thought ok!
Next I was getting a STRONG odor of SPIRITS!!!!!!! So I start investigating
Thinking my water supply was too hot or stopped, ( not condensing, only steaming )
( remember you cannot see the crap ) but NO?
I noticed a couple water droplets on the rear seal
So I put my hand back there ( instant steam burn, ) oh crap, shut her down,
Broke the nut on the thumper ( vacuums issues ) fixed the gasket, fired her up, bam,
back in action!
WARNING:
If anything goes a RYE ( lol )
Just turn off heat! Don’t risk it! I was stupid but lesson learned!
My first leak! ( hopefully last! ) rookie mistake!
And a bad one!
Which brings me to my next hack;
Stainless pot still’s with 4 clamps,
Use these paper fasteners to add extra clamps around lid,
As these types of stills get used more the lid tends to WARP, just a bit, but the 4
Factory clamps can no longer hold it flat, so I added 1 between each clamp,
But now ( since leak ) I got 3 between each clamp!

See pics:

J Dot
STAY SAFE YOU GUYS!

The pics!

[J Dot]

Ok guys,
It’s been 16 hours!

So onto step 2

As you can see ( pic below ) our corn has SWELLED
Substantially, we need to strain out all the water,
( pic ) then add our soaked corn to the rig bucket.
( pic ) , close bucket, and place on rig, then set timer,
Turn on, and let her rip’
We only need to SPRITZ the corn with a spray bottle ( distilled water )
To keepcorn moist!
( NOT WET, not DRY EITHER )
If you place your hand in and grab a handful of corn, let it go,
And pull your hand out, your hand should be a bit SLIMY , not wet,
Not dry! Rubbing fingers together ( slimy ). This is the hydration we want,
Too wet will mold, to dry will stop the malting process!
As the grains mature and root, we will cut back on the water a bit!
As heat will increase! ( this is where the tumbler really does it’s job ( turning )
The corn , to release heat, and distribute moisture evenly!

See pics and VIDEO below ( finally figured YouTube out )

J Dot
{:0)

Video
Here is a link:
https://youtu.be/-z4QE1onu1I

Pics:

[Fart Vader]

Very nice documentation J Dot. A lot of good ideas in here also.
I'm pretty sure I'll use a couple of them.

Kudos.

[Manc]

Hi J.dot

That's awesome love the build keep up the good work.

Lee

[J Dot]

Hello, Everyone,
Well it’s day 3, and our malt is going well,
See pictures below!
I spritzed it today with a bit of distilled water,
But looks great nothing happening yet, but still early!
Rig is doing well, no issues yet!

Also wanted to share 2 other items below,
In pictures:
First was a visitor to our job today, a gorgeous BLACK WIDOW
spider, it was very large, biggest I’ve seen! About the size round
As an American half dollar coin ( legs and all )!
I released her into the woods! But not before shooting some pics!
And video!

Then
I came across a prescription from 1962!
You're gonna laugh!
( cough syrup recipe )
( please let me know your thoughts! )
I LOVE IT!

J Dot
{:0)

Ps: Fart Vader, and Manc,
Thank you both! And yes having so much fun with you all,
Sharing and trying new things! And if I can just help 1 other,
Than I’m good with that! Makes it all worth it! Take care!

Pics:

[J Dot]

Hello
I talked earlier about a DEPHLEGMATOR,
But obviously, did not clarify!
So I dug our my old drawings,
One shows a Dephlegmator, other shows a
SHOTGUN CONDENSER, if any of you would like to
know how they both work. Or how to build one?

J Dot
( figured while we wait, might be fun! )

Pics:

[J Dot]

Ok,
DAY 4, is upon us!
Malt is looking PERFECT, in my tumbler rig,
Everything working as planned, no issues, YET!

See pics below of my corn starting to sprout,
Yes we are seeing action, little corn is happy,
And thriving!

I grabbed some out, and felt I needed to spritz it,
But I’ve not used much water at all, much less than
Than malting in a pan with towel over it!
So that is a plus!
The smell is great, like fresh corn!
( if you were to peel a ripe corn back, take a bite,
THAT SMELL, where you took a bite at! )

J Dot

Ok ,
The pics!

[J Dot]

And Lastly,
Cannot forget my good friend,
And new friends, who want to see the rig operate!
Here is a video I just shot, day 4 malting Rig ,
In operation!

J Dot

Enjoy:
https://youtu.be/pdJYXkCgN0I

[J Dot]

Hello,
DAY #5, ( day 4 in our tumbler ) 1 day to soak corn!

So,
The malt is still looking great, healthy and happy,
I’m adding a bit more water now, as the corn is
taking off, and needing more!

But I think we have success , my friends,
Still smells great, looks great, and is growing like
Wildfires!

I did see one hitch developing , I see my drive wheel burnt
Through my traction tape around bucket, causing a small pause
In rotation, but I might go ( GRIP TAPE ) like I used to use on my
Tony Hawk Skateboard, back in the 80’s! Lol

Ok
Some pics below:

Also wanted to add a not here:
NOTE:
I was thinking about running this batch of malt corn, as a
CRYSTAL MALT, with walkthrough and pictures ( as usual )!
If any of you are interested, pm me or post here! I’ve never done
It, because it is SUPER TIME CONSUMING! But always wanted to try!

If my good buddy, could possibly offer direction on STEWED MALT,
I’d gladly run that as well ( same walkthrough )!

I also learned you can malt RICE! HMMMMMmmmmmm!
( any grain really, just not sure the RICE advantage,
as rice offers very little sugars ) BUT remember SAKI,
And it’s potent powers!

So like I said if you wish to watch or learn CRYSTAL MALT
And the process, let me know,I’d be glad to do it! I

J Dot

The pics:
Today ( day 5 )