Keg Boiler Build - Need Advice

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Keg Boiler Build - Need Advice

Postby Amfamora » Fri Apr 21, 2017 7:10 pm

Hi All.

At the point where I need to have the ferrules tig'd to the keg. Im going to have to find someone to do this for me, I have little welding experience.

Whats the best process for preparing the keg? Drill the holes first then have the welding done or weld the ferulles first then make the holes?

If anyone in Brisbane/Toowoomba area is available to help me out for some dollars or can reccomend a place they have used to have this work done would be much appreciated.

Cheers :text-thankyoublue:
Amfamora
 
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50l Keg Boiler
4" Bubbler

Re: Keg Boiler Build - Need Advice

Postby j0sh2008 » Fri Apr 21, 2017 9:18 pm

I used Kennedy welding @ Coorparoo in briss to get some work on my boiler done.

They did a good job and was a decent price.

I got a 4" & 2" ferrule and a drain port TIG welded for $100 i think from memory
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Re: Keg Boiler Build - Need Advice

Postby azzman » Fri Apr 21, 2017 11:31 pm

ive used them many times also. they drill and weld for that price. good job. i know a few others around this place who have also used kenedy welding :handgestures-thumbupleft:
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Re: Keg Boiler Build - Need Advice

Postby Amfamora » Sat Apr 22, 2017 7:50 am

Cheers guys. Will give them a holler.
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50l Keg Boiler
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Re: Keg Boiler Build - Need Advice

Postby Amfamora » Sat Apr 22, 2017 3:09 pm

Went to the green shed today grabbed some Heavy Duty 10amp extension cords to chop for the elements which are still on the way.

Power Controller has been ordered. Will be running 2x 2400w elements.

Just got to work out a parts list for the drain and some legs.
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Amfamora
 
Posts: 56
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Location: Lockyer Valley, QLD
equipment: T500 Pot and Reflux :/
50l Keg Boiler
4" Bubbler

Re: Keg Boiler Build - Need Advice

Postby Professor Green » Sat Apr 22, 2017 6:48 pm

Is that an "off the shelf" power controller Amfamora? It looks the business!

Cheers,
Prof. Green.
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Re: Keg Boiler Build - Need Advice

Postby Amfamora » Sat Apr 22, 2017 8:50 pm

It is... advertised as 6000w capable. Clubby has a thread with one he has recieved and the case open :)

viewtopic.php?f=60&t=10587
Amfamora
 
Posts: 56
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50l Keg Boiler
4" Bubbler

Re: Keg Boiler Build - Need Advice

Postby Professor Green » Sat Apr 22, 2017 9:43 pm

Thanks mate.

Cheers,
Prof. Green.
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Re: Keg Boiler Build - Need Advice

Postby Amfamora » Tue Apr 25, 2017 2:07 pm

Managed to get a bit more done on the build today before my dremel decided to take a permanent nap :angry-banghead:

Wired up one of my 2400w elements with 2.5mm core wire instead of my previous choice of 10amp HD extension lead. A little overkill but will be a fair run to an external circuit outside the shed. My second element will be wired up when the power controller arrives.

Need a new dremel now to finish cleaning up the 4" and 3" holes before starting on the holes for the elements.

Good Times.
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Posts: 56
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Location: Lockyer Valley, QLD
equipment: T500 Pot and Reflux :/
50l Keg Boiler
4" Bubbler

Re: Keg Boiler Build - Need Advice

Postby Amfamora » Sat May 06, 2017 11:33 am

Hi Again All,

At the point of trying to decide where to place the hole for the second element. Im considering the spot marked with the x but being on a curve creates a couple of mm gap between the bottom of the ferrule and the wall of the keg.

Will whoever I get to weld this all up for me be able to span a couple of mm gap or does it need to be as flush as possible. No welding experience so sorry if it seems like a stupid question.

Do I need the holes big enough the ferrule needs to sit inside them to avoid this problem? Can I put them closer together at the same height almost parallel then bend the elements so they wont touch?

Doing it as I am, after the welding I do plan to have the holes ground back inside the ferrule with a die grinder :)

Cheers
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50l Keg Boiler
4" Bubbler

Re: Keg Boiler Build - Need Advice

Postby Aussiedownunder01 » Sat May 06, 2017 12:29 pm

I would not try bending an element
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Re: Keg Boiler Build - Need Advice

Postby Amfamora » Sat May 06, 2017 1:02 pm

Ive just yolo'd it :)

Ill either get the ferrules welded on then do some gentle keg panel beating to splay out the angle of the ferrules. Or ask who ever I get to do the welding if they can cut/grind the bottom of the ferrule before welding to change the angle slightly.

Whats done is done but confident it will work out in the end.
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Amfamora
 
Posts: 56
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equipment: T500 Pot and Reflux :/
50l Keg Boiler
4" Bubbler

Re: Keg Boiler Build - Need Advice

Postby Professor Green » Sat May 06, 2017 9:12 pm

I reckon you could get them to weld the ferrules on such that the elements sit parallel.

Cheers,
Prof. Green.
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Re: Keg Boiler Build - Need Advice

Postby Amfamora » Sat May 06, 2017 9:19 pm

Im hoping so, just not sure of the tolerance as far as covering gaps with tig. Ive done my share of shady mig welding but want this to be done neat :)

Im probably over thinking it all....
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equipment: T500 Pot and Reflux :/
50l Keg Boiler
4" Bubbler

Re: Keg Boiler Build - Need Advice

Postby Amfamora » Sat May 06, 2017 10:23 pm

*Side Note*

Dont replace a dremel with a dremel. Get a foredom... even a chinese clone.... Les rippems more torque.

Cheaper than a half decent dremel :)
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Amfamora
 
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Location: Lockyer Valley, QLD
equipment: T500 Pot and Reflux :/
50l Keg Boiler
4" Bubbler

Re: Keg Boiler Build - Need Advice

Postby hillzabilly » Sun May 07, 2017 2:36 pm

On my element ferrules I welded an extra 25mm of 2inch to the ferrules so I could run them both paralel at the same low height,wilst giveing plenty of room for the clamp,like this.cheers hillzabilly :handgestures-thumbupleft:
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Re: Keg Boiler Build - Need Advice

Postby Amfamora » Tue May 09, 2017 4:39 pm

Why the freck do kegs have to be round......

Ill get it sorted. 4" 4 plate almost here..... need to get this boiler done stat!
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Posts: 56
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equipment: T500 Pot and Reflux :/
50l Keg Boiler
4" Bubbler

Re: Keg Boiler Build - Need Advice

Postby Amfamora » Tue May 09, 2017 5:27 pm

hillzabilly wrote:On my element ferrules I welded an extra 25mm of 2inch to the ferrules so I could run them both paralel at the same low height,wilst giveing plenty of room for the clamp,like this.cheers hillzabilly :handgestures-thumbupleft:


Did you have your element holes cut to the inner or outer diameter of the ferrule?
Amfamora
 
Posts: 56
Joined: Thu Jun 09, 2016 5:23 pm
Location: Lockyer Valley, QLD
equipment: T500 Pot and Reflux :/
50l Keg Boiler
4" Bubbler

Re: Keg Boiler Build - Need Advice

Postby hillzabilly » Wed May 10, 2017 1:01 pm

I cut to the outer ,so that there is a little bit of the extra 25mm by 2inch inside the keg,was easier and I did not have ta trim funny angles of the ends,has worked perfectly for me,with a little clean up with a flap wheel.cheers hillzabilly :handgestures-thumbupleft:
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Re: Keg Boiler Build - Need Advice

Postby scythe » Thu May 11, 2017 6:47 pm

Can my advice be don't do it?
Or is it too late for that?

A 50L milk can boiler is a comparable investment once you really add up what a keg boiler will cost you.
And a 100L milk can does future proof you but it does take a bit longer to run.
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