Brew/boil kettle build from 15g keg.

[bitter]

I am just starting this as I picked up a a keg to turn into a brewing kettle for mashing and also for boil kettle for my beer making.

I will take pics over the weekend.

First the top is cut out of the keg.

I have 3 holes 1 for an 220V 5500 Watt element

2 other holes both getting 1/2 npt coupler welded in.
-1 for sight glass
-1 for stainless ball valve for drain to fermentor

I'm doing a DIY site glass have some simax (pyrex like) glass tub on order for it

Need the following still
-stainless eye bolt
-Cover to protect the tube with slot to view level
-90 stainless or brass fitting (want stainless might need to live with brass) that is 1/2" npt on one side and 3/8" or 1/2" compression ont he other side
-a couple food safe silicone oring to seal the site glass
-Extra other oring for spacers for the Protection tube.

Will take pics as I go.

Setting things up so can put a false bottom in the kettle too if I want but most likely just use a screen to help filter our any big chunks or hops when making beer.

B

[Snackson]

Need the following still
-stainless eye bolt
-Cover to protect the tube with slot to view level
-90 stainless or brass fitting (want stainless might need to live with brass) that is 1/2" npt on one side and 3/8" or 1/2" compression ont he other side
-a couple food safe silicone oring to seal the site glass
-Extra other oring for spacers for the Protection tube.

Will take pics as I go.

Setting things up so can put a false bottom in the kettle too if I want but most likely just use a screen to help filter our any big chunks or hops when making beer.

B

If you have spare copper pipe and a dremel, I've seen that cut up with slits for the protector for the sight glass. I've used the polycarbonate sight glasses from Brew Harwdware and love them. Great customer service too. Plus you might find the other stuff you need too. Looking forward to the pics, who doesn't love beer porn/ 'stillin porn?

[pythonshine]

Nice! will be following

[shadylane]

Ya have my attention also.

[yakattack]

Subed *grabs popcorn*

[ericrichards420]

I would use a 1/2" stainless compression fitting called a strait npt on the outside for your ball valve compression side inside for a dip tube past your false bottom.
This makes draining the kettle work correctly.

[bitter]

Dooh tried to take pics and camera battery is dead. Its charging so maybe later.

B

[bitter]

Here are some pics of the Keg wiht top cut off and the holes drilled

[bitter]

This is my Keg my Boka goes on. he welds, heater and ball valve will be setup the same as this.

B

[shadylane]

Looks good Bitter
Please use more words and pic's to explain the how and why

[ericrichards420]

That compression 90 you shared is brass and is not food grade, I would not use anything other than stainless 304 and up

[bitter]

The 90 is lead free, and temporary till I can get a stainless one. Not going to spend 17$ to ship a 12$ part, its for the site glass. Found ptfe seals also that I can modify to work with the compression fitting.

The larger hole in the keg is getting a nut welded on it for the heating element.

The 2 smaller holes are getting 1/2 npt coupler welded on. 1 is for a stainless ball valve and the other is for the site glass.

I am using a cooler for a mash tun but this will be a boil kettle. It will use it however for mashing with enzymes. I have a 1/2 ntp stainless plug in case I want to pull the site glass off (Might for enzymes with corn for example). I am making it so I can put a false bottom in the keg if I want but for now not doing that. For the most part this is a boil kettle or for cooking grains.

B

[ericrichards420]

Sounds like you have it figured out, I'm sure it will be alright. I would defiantly change out that brass fitting as soon as I could. even if it don't contain lead it will still croad and leach out something undesirable. anyways Good Luck, and cheers!

[bitter]

Boil kettle is done except for the sight gauge.
Even found a nice lid for it.
Might still add filter on inside of ball valve for mashing... but plan to use the cooler for mashing so might just put a filter in for hops.

Next will be the heater controller, SSVR just finally arrived.

B

[bitter]

Pyrex glass tubes (Actually simax brand) arrived. Got 10mm (just over 3/8") and 12mm (Just under 1/2"). Will work on the site glass this weekend. I am thinking a ptfe seal/oring and should be in business. Once I prove all works well will order a stainless 90 thats 1/2" NTP to 3/8" compression.

So I have 12 pieces of each just under 20" each (so 24 total lol )

B

[pythonshine]

nice work bitter! Should see you well.

[bitter]

t8x pythonshine

[bitter]

Now for the sight Glass did some work on it yesterday but camera battery was dead so finished things up to were I had to stop due to running out of things I need.

First the brass piece because I ordered 10mm (They did not have .375" simax so got closest size) would not fit.

I used the dremel to open up the compression nut and also the inside were the tube goes in.

The Simax was pretty long (About 3-4" over the keg) so I decided to cut it. I used a cutoff wheel in the dremel to score all around and then snapped it. After that I sanded the rough edge and flame polished the ends. After flame polishing I anieled the glass to decrease and stress rises from the first heating. It only affected the first 1/2" of so of the simax and its good for about 400C and open so no preasure buildup.. Plus I have another 23 tubes if needed

I tined the inside of the brass fitting with 96% Tin/4% silver solder. Just to ensure if I do use this even once nothing will leach. I boiled the part in vinegar after a getting a scrubing and soapy water. I then used so fores to clean it and degrease it.

I installed the brass piece with PTFE tape and then used PTFE tap wrapped around the tube to make a gasket. IT fit very firmly into the brass piece so far to good in a quick water test. Then the Nut with tighted down to compress the bulgde of PTFE tape at the top (about 30-40 wraps 1/8" wide) I used to create an oring.

Once installed I found the center piece fo the keg and cut it to length. Cutting it with a dremel has shown me that I can't cut the slot in the stainless tube with the dremel.. so might get replaced with 1/2" copper pipe. I need some for another job anyways so that will be easier.

The things I need to finish:

More Dremel cut off disks.
Eye bolt the right sized eye9
Some orings for spacers for the Stainless or copper protection tube, Might just make some using PTFE rod (If I can find it). Be perfect for top and bottom...
Eventually a stainless 1 MPT / 3/8" or 1/2" compression 90 to replace brass one.

Now that I used more words this time some pic

[shadylane]

Good job Bitter

[yakattack]

Good job mate. Glad to see things coming together for your build.

[Danespirit]

That looks good..
Perfect welding too..

[bitter]

Thanks guys.

Wish I could take credit for the welding... I can't I found a local guy that does tig and as you can see he is pretty good.. at least to someone that does not weld

B

[bitter]

Only took like 2.5 hours... ground a slot in the stainless...... got there eventually..

It does not look so great... but its functional... and that is all that is important.

B

[ericrichards420]

Bitter, I'm a pipe welder. One thing I learned on my build is welding even sch10 stainless pipe is a lot easier then welding things like kegs and small fittings not to mention 2" stainless tubing. If the weld turns out to look good than great! if not the important thing is that is will hold shucked corn, or better yet what its built for.
Your build is looking good and it will serve you well for many years to come.

[bitter]

Eric,

Thanks for the comments. I feel this will be the last boiler I need for my beer and mashes for some time.

B

[likkerlover]

seems to be coming together nicely. good work. ditch the lid when making beer though. i read somewhere that boiling your wort puts off a sulfur, i believe, that you dont want in your beer

[bitter]

Thanks,

The lid is for then I want to do enzyme mashes for gelatizing grain for example... I want to try booner's corn for example, Flaked barely, oats and a similar all rye mash for example. Once cooked to the cooler till time for enzyme 2 to ensure as much time as possible for the best conversion I can get.

For beer the lid will only be used for coming upto temp faster. Also hoping to insulate the sides of the kegs too so can use less power. Mos the recipes I am looking at are taking say 6+ gallons down to 5.25 gallon on the boil. I also like to skim crap off during the boil before the hot break when making beer. Til now I have done most extract or brew in a bag.. going all grain now.

B

[bitter]

Finished the sight glass... just need numbers based on volume.

B

[yakattack]

Looks good buddy. Now you just need a led light to illuminate it. :p

[still_stirrin]

I'm a big fan of "analog" too.

Good looking job there bitter. Keep it up.
ss