8" plates

[30xs]

Can could use a piece of plate steel and spin it in your lathe using a larger bolt chucked in the lathe. The double sided tape the copper to the steel disc and use a grinder with a flap wheel to buff the copper down to the steel size. It would give you a pattern to build plates off of in the future.

[shadylane]

I'll probably bolt both plates between two pieces of plywood and chuck it into the lathe to machine everything down to size at the same time.
When I'm done the plywood will be exactly the right size for a future pattern.

[30xs]

Similar results. But the steel plate would allow no hole in the center of the copper.

[shadylane]

There's going to be several holes in the plate anyway, most likely one of them will be right in the middle.
Besides I'm too lazy to make a fixture out of steel.

[Saltbush Bill]

Holes are easily fixed with a blob of solder anyway.

[shadylane]

This is as flimsy as it looks, but it works.

[shadylane]

Once the plates were ground to size, I installed one of them and it fits perfectly using an unmodified triclamp seal.
I hate to admit it but I'm surprised.

[Copperhead road]

Nice job Shady!
Have you made the copper cylinder sections yet?

Your method of using the lathe & flap wheel has worked really well giving you a uniform circumference for a perfect seal.

[shadylane]

Nice job Shady!
Have you made the copper cylinder sections yet?

Not yet, but that's next on the menu.
I'm not sure how tall to make the cylinder sections, the sheet copper I have is 12 inches wide. I'm arguing with myself about whether to use it as is or cut it down to around 8"

[shadylane]

Thank to 30xs for the idea. Here's how it did it.

[30xs]

Thank to 30xs for the idea. Here's how it did it.

Glad I could offer a useful idea. I’ve always enjoyed you seeing your projects come to life.

[shadylane]

Started on the cylinders to contain the plates. They will be 9" tall.
Maybe tomorrow I can get some welding done.

[Copperhead road]

Started on the cylinders to contain the plates. They will be 9" tall.
Maybe tomorrow I can get some welding done.

Are you Tig welding the cylinders Shady?

[shadylane]

That's the game plan, wish me luck.

[30xs]

Thank to 30xs for the idea. Here's how it did it.

From that image I did mine backwards. I relieved the top of the module to make assembly a bit easier dropping the plate in and then setting the gasket and next module. You can always bench assemble upside down then move it to the boiler though.

[shadylane]

Here's how it could be done using thin O-rings but it would be a pain to keep everything aligned while putting on the clamp.

[30xs]

I made my plates out of flattened 4”. Being about an 1/8” thick I don’t think the o-ring route would have worked for me. I do use a couple wraps of teflon tape around the edge of my plates just to make sure there’s no weeping around the edge. Completely pointless on perf plates other than adding a little friction to keep things from shifting during assembly.

[shadylane]

I got the ferules welded on one of the cylinders, it will hold water but the welds are kinda ugly.
Another pass will make it look better.

[shadylane]

The sight windows, plates and dephleg still need made but I just had to see what it looks like on the boiler.
It's not as big as the pic makes it out to be,

[Saltbush Bill]

Looks cool I think, what size is that boiler.

[shadylane]

16ish gallons usable, 18 if overfilled.
Around 10 years ago I made the boiler out of a SS sand filter.

viewtopic.php?t=57812

[tommysb]

How was it to weld the copper to ss shady? It was TIGd right? What filler must you use?

[shadylane]

No filler, only the copper on the cylinder was used.
It welded easily, but my hands shake so much now it doesn't look very good.

[Setsumi]

The sight windows, plates and dephleg still need made but I just had to see what it looks like on the boiler.
It's not as big as the pic makes it out to be,

So, only 2 plates? You are short changing us the veiwers!

Good job, please continue.

[shadylane]

Time to start thinking about the sight windows.
I have 3" copper ferules and clamp on windows.

[shadylane]

So, only 2 plates? You are short changing us the veiwers!

Two plates are enough, when the boiler is charged with low-wines.
1st distillation happens when stripping, 2nd happens in the boiler and I get two more distillations from the plates.
If I was running mash in the boiler another plate or two would be needed to clean up and polish the whiskey.

[Saltbush Bill]

Keep those sight glasses in as close as possible to the column for maximum viewing.

[30xs]

Time to start thinking about the sight windows.
I have 3" copper ferules and clamp on windows.

I’d mount them in the lower 1/3. Closer to the top of bath depth. Easier to see the plate if you are lower.

Looks like you might have enough room to cope the ferrule and solder it directly and still be able to have clamp clearance.

[shadylane]

Here's what I'm thinking, have the sight glass as low as possible and angle it slightly for a better view.

[Yummyrum]

I remember Stubbydrainer did that on Old CCSC forum . Reckoned it stopped pooling in sightglass too

How about some LED lights in there too Shady