Brew Sculpture 101

Kenny Lucas · Post by **Kenny Lucas** » Fri Jun 29, 2007 9:14 pm

Things are looking good! I can relate to the gas plumbing issues...took about 25 trips to the local hardware before I got the correct lengths to come together. I got some orifices from Morebeer as well as the regulator.

Dwayne_Delaney · Post by **Dwayne_Delaney** » Fri Jun 29, 2007 10:24 pm

Here is a link that I came across awhile back. I don't know anything about the vendor, but they have a good selection and decent prices on burners.
http://allrecipeshopping.com/shop.asp?path=,60

Chris Norrick · Post by **Chris Norrick** » Fri Jun 29, 2007 10:49 pm

I found out today there is a place that sells a 1/2"NPT male to 1/8"NPT male fitting that is drill with a LP orifice. I didn't see it on their site so I emailed them and haven't heard back yet. I see More Beer has a custom made 1/8" threaded pipe with a orifice. Its $5 which I find a bit extreme. I hope this other place comes through. If it does I'll post the info.

I measured for all the gas pipe tonight. Here is a full scale PDF of my plumbing plan CLICK ME. I assume one of the hardware stores does custom cutting and threading of black pipe. I hope Ace does as it about 60 seconds from my house. I've been there every day this week! I'll probably spend more there tomorrow. I don't mind giving them money as it's so close to the house that I don't want them to go out of business. They really do have an amazing assortment in there.

I cut off one of the stainless dip tubes from one of my converted kegs to the width of the cart and attached it. It's a cross between a handle and a flexible hose rack. I hope it's not too close to the burner to melt my hoses.
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I used some good 'ol JB Weld to attached the little 6" pieces that help stabilize and trap the kegs. It's supposed to be good to 500*F, we'll find out!
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Chris Norrick · Post by **Chris Norrick** » Fri Jun 29, 2007 10:52 pm

Dwayne, is your burner one of the ring type with the holes? I'm thinking of getting these as they are so much quieter than the ones I have now. How do they attach to the burner stand?

Dwayne_Delaney wrote:Here is a link that I came across awhile back. I don't know anything about the vendor, but they have a good selection and decent prices on burners.
http://allrecipeshopping.com/shop.asp?path=,60

Dwayne_Delaney · Post by **Dwayne_Delaney** » Sat Jun 30, 2007 10:58 am

There is a single bolt on the bottom center that mounts the burner to the frame. There are also tree small legs that could be used to stabilize the burner. See Pic.

Chris Norrick · Post by **Chris Norrick** » Sat Jun 30, 2007 10:38 pm

Ah, excellent. That's compatible with my set up. The ones I have now have a threaded post in the middle. If I switch out I won't have to modify anything! That's a first on this project. I just realized I'm going to have to get a LP regulator that has a flare fitting on the hose. Mine have the orifice built into them so they are unusable.

Let's see. I drilled and installed a "weldless" thermometer in the HLT and also drilled a hole for a sight gauge. My step "uni" bit is really dull so this took awhile. I tried to sharpen it a couple a times.

I cut the hard copper and partially assembled the homemade sight gauge. I'm awaiting a order from McMaster to complete it. It's really simple and I hope it works. I'll post the pics and instructions when I get all the parts. Basically: a short 3/8" NPT brass nipple, two brass locknuts, a silicone o-ring (or two), a 90* elbow, a 3/8" X 3/8" threaded barb, about 2 foot of 3/8" ID vinyl hose, about 2 foot of 1/2" hard copper pipe, a copper end cap, and a stainless eye bolt and two stainless nuts. I cut about 1/3 of the copper away down the tube so you can see the vinyl inside it. The copper is basically just there to support the hose, and look pretty.

Chris Norrick · Post by **Chris Norrick** » Sun Jul 01, 2007 10:51 pm

Didn't do much today. I cut a piece of laminated particle board to set the propane tank on. Got a couple of pieces of my gas pipe cut and threaded at Lowe's. Ace doesn't cut or thread. The machine couldn't cut one of the really small pieces I needed so I'm using a short nipple with a coupler. Should be interesting. I ordered a regulator and two orifices. I hope they are the correct size.

Here is where it stands.
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I decided to take the insulation off the mash tun and make it so I could slip it on and off easily as it's going to be really close to flames on the cart. The insulation is that mylar bubble wrap stuff about 7 layers thick. It's what I had laying around at the time when I first made the tun. Anyway, as I was taking it off I noticed a horrid smell. Trapped in between the layers was moisture, mold, grain, etc. It was also melted to the tun. Pretty nasty. I'm not sure I'm going to replace it. I'm running a HERMS so the mash is constantly recirculated through a coil in the HLT picking up heat so I'm not sure I need it. I have a post up on the green board asking that question.

Looks like most of my other parts will be delivered on Tuesday so the 4th is going to be busy running the gas pipe and maybe a test!

Kenny Lucas · Post by **Kenny Lucas** » Mon Jul 02, 2007 3:56 pm

I can see it now. The 4th... gas pipe... test... instant homemade fireworks show on the north side. Should be able to see for miles!

Chris Norrick · Post by **Chris Norrick** » Mon Jul 02, 2007 10:22 pm

I should sell tickets to the show.

Hey Kenny, what is that insulation on your mash tun called? ARMAFLEX?

Kenny Lucas · Post by **Kenny Lucas** » Mon Jul 02, 2007 10:37 pm

The black stinky stuff is called Rubatex. From Grainger (if you have trouble getting items from there I have a contact there).

Chris Norrick · Post by **Chris Norrick** » Tue Jul 03, 2007 10:12 pm

Woo Hoo! It's just like christmas what that UPS truck pulls up. It was after 8 p.m. and I wasn't sure if it was going to make it. But my McMaster.com order came in and I got all sorts of metal goodies.

Picked up this cool "weather proof" switch box for the pump. A normal 110v switch fits inside. Seems like a better solution than the current method of yanking out the plug when things go haywire.
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Here is a pic of the other parts needed for a sight gauge/glass. I got the wrong o-rings

, these are 3/8" ID, I need some that fit 3/8" pipe which is a pipe ID measurement not OD. Plus they are too thin. I need some thicker ones to seal up the bulkhead. At lease the locknuts are correct, I wasn't sure when I ordered them. I'll head to Ace and see if they have some suitable o-rings in the morning to finish up that project.
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And here is a layout of the gas plumping. And a shot of it partly together. I had to many beers to finish it. This double-hopped american amber is just too tasty.

So far things look like they are going to line up.
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Chris Norrick · Post by **Chris Norrick** » Wed Jul 04, 2007 5:21 pm

Finished tightening the last few connections of the gas plumbing and set it in place with some clamps. It actually lines up really well. I still need the regulator and gas orifices. Although I'm half tempted to just cut the hose that came with the burners, push it on a hose barb with a hose clamp and call it done. I'll attach the pipe to the cart once everything is in place.
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I also finished up the sight gauge. It's really a straight forward assembly.

An outside shot, an inside shot.
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The elbow attached. The hose barb and hose attached with clamp.
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The top stainless eye installed. If you are smart you won't locate your gauge in front of the handle and you can drill into the top of the keg (chime) and not the body

. And a finished shot.
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Used some JB Weld to attach the switch housing and wired up the switch.
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I removed the two layers of melted and moldy insulation from the mash tun and re-taped the top and bottom of the remaining layers really well with aluminum tape. This should seal it up to prevent future messes. I also added in some velcro so it is easy to take off during the boil (so it doesn't melt being so close to the burner!)

Chris Norrick · Post by **Chris Norrick** » Mon Jul 09, 2007 9:50 pm

I received the last of the parts today. The two orifices don't work with the fitting I have so this is my solution. I cut the hose that came with the cheap turkey burners. Added in a barb and screwed that into a 1/2" fitting. This mess was so long I had to angle the burners 45* and shift the pipe down. This did have an advantage as the pipe now runs right along the frame. Made it easy to secure with the existing bolts and some galvanized metal strap.
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The 20 psi regulator seems to work just fine. It as a needle valve adjustment and combined with the ball valves I have some fine control over the flame. With everything attached I wheeled out the beast from the garage and pressure tested the gas lines. No leaks detected so I lit the burners! WooHoo!!!
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Most of the JB Weld burned off my little supporting pieces so I'll need to actually weld those back on. I also hacked these wind screens off the crappy turkey burners. I had to cut them down a little to fit. It was short work with the angle grinder. Those will need tack welded too.
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I ran the system with water and still seem to have trouble pumping from the mash up into the recirculation coil, or even to the top of the HLT. I had this problem before the cart was built. I think the pump has enough gusto so I must be getting air into the system somewhere. Probably a result off all the quick disconnect fittings. Another downside is those things get hot! I'll likely rig up some hard pipe in the future. I also have a leak in one of the compressions fittings. It goes to the "wort in" pipe for the post-boil whirlpool. I tightened it down so hard I cracked the nut. Crap.

Well, it mostly seems to work as I envisioned. I ran it till it got dark and then flushed the water out. I got everything put away and wheeled it back into the garage in about 10 minutes. I didn't run all the systems as on brew day but I gave it a good trial run. I didn't even need the fire extinguisher.

Justin Rumbach · Post by **Justin Rumbach** » Tue Jul 10, 2007 10:55 pm

It's a thing of beauty Chris! *wipes tear*

ps - I want to come down for a brewday sometime! Hopefully I'll see you at the SWIRCA fest.

rbirkle · Post by **rbirkle** » Thu Mar 06, 2008 12:17 pm

I think I am going to try to make something like this. I have enough steel and I have access to a welder and all the tools. My buddy's is also going to hook me up with some burners. So about the only thing I need is a pump. I am on vacation today and Friday so I have plenty of time this weekend to play.