Converting keg to kettle., Questions about tools, welding, etc. Options

[barbarossa]

So I'm going to start keeping my eye out for some kegs to convert to kettles. I think I'm just going to forget getting an aluminum pot and do this the right way. Since I don't have money I definitely can't afford a Sabco setup, but if I can find a keg for not very much I'd like to try to convert it.

I'm not very good at DIY type projects but I'm starting them a lot more since I'm homebrewing. I don't mind doing the project I just don't know how to go about it.

Anyway I read the FAQ and know I need to use something like a dremel to cut a hole in the top of the keg and then drill a hole and put in a bulkhead.

Newbie Question #1: What the hell is a dremel and where do I get one. I googled this and found the dremel company, etc., but I don't know what tool I need.


I'll probably be asking a friend with a lot more technical know how to help me with this. we could possibly weld some stuff at his house, so is it a lot cheaper to weld the bulkhead or should I just order one of the weldless fittings? If the weldless, any idea how much they run for?

Thanks.

[RommelMagic]

So I'm going to start keeping my eye out for some kegs to convert to kettles. I think I'm just going to forget getting an aluminum pot and do this the right way. Since I don't have money I definitely can't afford a Sabco setup, but if I can find a keg for not very much I'd like to try to convert it.

I'm not very good at DIY type projects but I'm starting them a lot more since I'm homebrewing. I don't mind doing the project I just don't know how to go about it.

Anyway I read the FAQ and know I need to use something like a dremel to cut a hole in the top of the keg and then drill a hole and put in a bulkhead.

Newbie Question #1: What the hell is a dremel and where do I get one. I googled this and found the dremel company, etc., but I don't know what tool I need.


I'll probably be asking a friend with a lot more technical know how to help me with this. we could possibly weld some stuff at his house, so is it a lot cheaper to weld the bulkhead or should I just order one of the weldless fittings? If the weldless, any idea how much they run for?

Thanks.

Here are some examples of a Dremel.
http://www.amazon.com/Dremel-400-6-90-Vari...2841&sr=8-1

http://cgi.ebay.com/New-Dremel-400-XPR-ROT...1QQcmdZViewItem

[sfranklin]

I used my Dremel because I already owned one and did not want to purchase an angle grinder. If you go the dremel route you must buy the reinforced cutting wheels. I went through at least 4 cutting the top of my keg. Also, while it seems obvious, you MUST wear EYE PROTECTION. When a cutting wheel goes it shatters. I have found the dremel to be one of my useful tools.

Sam

[BFB]

A cheap angle grinder and a cut off wheel will also work fine. You can pick up a cheap one at like a Harbor Freight or soemthing like that. Your big box stores probably also have a unit that's nice but doesn't cost a fortune.

If you know anyone with a welding shop you can see if they could plasma cut it for you. Sometimes those guys work for beer. (IMG:style_emoticons/brewboard/wink.gif)

[Mike H]

A word of caution... If you don't even know what a dremel is, then I imagine you've never used anything like it. I'm not sure if cutting the top out of a keg is the right place to start. Walk before you run....

Mike

[dc2002]

I have two keggles that were converted in two different ways.

1. Cutting the top off. On one of them I used a buddy's sawsall and the hole is not very round but it only took a couple minutes to do it. On the other one I used a dremel type rotary tool with fiberglas reinforced cutting discs. The hole is perfectly round but it took about a half hour to complete the cut. With the dremel you just do a very shallow "score" all the way around over and over again.

2. Adding a port. On one of them I drilled the hole with a step bit and then took it to a local welder that advertises stainless welding. I had him weld a 1/2 coupler to the outside. Works great and cost me an extra $20. On the other one I again drilled the hole with a step bit except this time I just used a weldless kit on it. No leaks yet, works great.

In summary, if I were to convert another keggle, I would use the dremel method to cut the top off and start with a weldless kit for the port. The hardware cost would be the same anyways. If it leaks you can always bring it to a welder in the future. Save yourself the $$$.

Also I got my kegs from a local brewery - called them and asked if they had any out of service kegs for cheap...I think they were $10 a piece.

[dadzcool]

I have two keggles that were converted in two different ways.

1. Cutting the top off. On one of them I used a buddy's sawsall and the hole is not very round but it only took a couple minutes to do it. On the other one I used a dremel type rotary tool with fiberglas reinforced cutting discs. The hole is perfectly round but it took about a half hour to complete the cut. With the dremel you just do a very shallow "score" all the way around over and over again.

2. Adding a port. On one of them I drilled the hole with a step bit and then took it to a local welder that advertises stainless welding. I had him weld a 1/2 coupler to the outside. Works great and cost me an extra $20. On the other one I again drilled the hole with a step bit except this time I just used a weldless kit on it. No leaks yet, works great.

In summary, if I were to convert another keggle, I would use the dremel method to cut the top off and start with a weldless kit for the port. The hardware cost would be the same anyways. If it leaks you can always bring it to a welder in the future. Save yourself the $$$.

Also I got my kegs from a local brewery - called them and asked if they had any out of service kegs for cheap...I think they were $10 a piece.

+1...I have converted three kegs and am a very experienced DYIer....I think that using the weldless fittings makes more sense....you can find them at any good website like MoreBeer.com....MidwestHomebrewing.com...etc......just google for homebrewing supplies and you will find numerous sites....good luck!

[stangbat]

Dremels are great tools and having one around is nice. But I would recommend using an angle grinder and cutoff disc to cut the top out. You can get a 4" angle grinder from Harbor Tool or Cummings Tools for $10 and a disc will be no more than $2. I started to cut out a keg with my Dremel and quickly realized that it was going to take way too long. Yes it can be done, but I didn't want to sit there for half an hour and go through who knows how many cutoff wheels.

As for the port and valve, a step bit (Unibit) works great for the hole. They can be expensive if you buy them at HD or Lowes. I got a set of four step bits from Costco for less than the price of one at HD or Lowes.

As for the weldless fittings, they work fine and are DIY. Nothing wrong with having a coupler welded in if you can get it done, but if not then weldless works fine. MixnMatchBrew sells them for the best prices I've seen:
http://www.greatbargain.net/order/index.html

[Brewmasterash]

I would suggest the plasma cutter route for the top. By the time you buy a Dremel tool and the necessary bits, you could likely have 3 or 4 keggles done by a metal shop. The one close to me will cut the top and grind the edge for $10.00. The total time is about 5 mins. and the cut will be nice and straight. If you want to DIY, you can still make the ports for any valves on the keggle.

[barbarossa]

Thanks for all the responses. I know I am really new to this and pretty bad at DIY stuff but I don't realistically see myself dropping the sort of $$ it would cost to buy the kind of rig I want new. I will have to do it myself over a few years and hopefully I will learn something.

I will definitely check the weld shop, although the reason I was asking about the tools is that I have a friend with a pretty extensive set of toys in his garage. I think he would help me do this, and I think now that I know the concept it's a fairly simple idea.

Stangbat, thanks for the links on the weldless fittings. I had been seeing them for close to $40 and was thinking there was no way in hell I was going to pay that. I have a ball valve already that I was using on my mash tun, but I converted it to the super simple Denny method so I might try to incorporate that. Then again I may just buy the $18 kit and save this ball valve for later.

[Bobby_M]

An angle grinder is a pretty common tool for anyone who plays with metal. See my video for a trick way of cutting clean holes repeatedly. http://www.youtube.com/watch?v=LthGdMk_avk

[kegcutter]

An angle grinder is a pretty common tool for anyone who plays with metal. See my video for a trick way of cutting clean holes repeatedly. http://www.youtube.com/watch?v=LthGdMk_avk

Bobby: I have been cutting sanke pots for years with the string/marker technique. Thanks for the detail on the jig. Great Video........

[beerpilot]

I would suggest the plasma cutter route for the top. By the time you buy a Dremel tool and the necessary bits, you could likely have 3 or 4 keggles done by a metal shop. The one close to me will cut the top and grind the edge for $10.00. The total time is about 5 mins. and the cut will be nice and straight. If you want to DIY, you can still make the ports for any valves on the keggle.

Would'nt that blow slag all over the inside of the keg? Seems a grinder would be a less messy route.

[Swagman]

Would'nt that blow slag all over the inside of the keg? Seems a grinder would be a less messy route.

Fill with water no slag and it takes appox 30 seconds with fixture.


Dominus Vobiscum


Swagman (IMG:style_emoticons/brewboard/cool.gif)

[tipstall]

What are you guys using for a pick up tube. I tried using a Bazooka T and with pellet hops it clogged. I'm thinking I'm going to make one out of copper, bent to pick up near the edge.