Modified Kegs

I purchased old kegs from the scrap yard. I also kept the receipts to show that I purchased them and that they weren't stolen. The next stp was to cut the kegs. You can search the web for some good articles on converting kegs. A few are: (http://www.schoville.com/brewing.php/kegconversion, http://www.texanbrew.com/article.php?story=20021110200202146, http://www.thegatesofdawn.ca/wordpress/homebrewing/keg_conversion/).

First you need to vent the keg or release the pressure out of the keg. This is fairly simple. All you do is take a large screwdriver and push down on the ball on the keg. Make sure you have a rag or something over the hole or you will get smelly old beer squirted all over you.

Once the pressure has been release you can mark the keg for cutting. On my kegs I cut the hole at 12 inches. I took a string and looped it around the keg tap and used a sharpie to mark the circle. I remeasured to mark sure the hole would be 12 inches. (Being paranoid that I would cut the hole too big.) The first time I cut the hole I used an angle grinder with a 4 inch wheel (found everything at Harbor Freight for about $20). The first hole I cut was about 10 inches then later I decided to cut the hole to 12" so that I could fit the false bottom that I wanted. The first hole I cut wasn't very circular. I think it was a combination of rushing and not used to cutting. The second time when I cut the hole to 12 inches I used a RotoZip which has a 3 inch cutting wheel. This hole came out better but again I think it is because I took my time. Once the hole was cut ithe edges were very sharp. I used a barrel sander attachment to my hand drill to clean up the holes (I also bought this at Harbor Freight for about $5). It took about 2 hours to cut 3 kegs and do the necessary cleanup of the hole. Oh, important point, I also used ear and eye protection while cutting the holes. It is really loud. If you are lucky enough to have access to a plasma cutter then take a look at this from YouTube: http://www.youtube.com/watch?v=_reRMz7YHic. I believe it took him 3 minutes to cut 1 hole.

Here is how mine turned out:

Next I cut the holes for the fittings. I used a drill to start the hole and then a step bit (also from Harbor Frieght). BTW, I use Harbor Frieght because they are inexpesive for the tools I am using. Good for tools that you will rarely use (like an angle grinder, step bits...). Here is the Keg with the hole cut out:

Then I added the weldless fittings and the false bottom and here is the final product:

The concept

This is just a quick entry that shows the sketch that started it all. I looked at pre-built brewing systems and found some really nice ones. The problem was the cost was a bit steep. That is what prompted the decision to build one of my own. Besides it was kind of a challenge. Anyway, here is the design I am shooting for.

Homebrew and Brew Systems

A few years ago I decided to start making beer. I had a few friends who were doing it and it kind of looked interesting. I thought it looked easy and it was something that I could do. If it turned out "ok" then I could share it with my dad.

When I started I bought a basic setup and was doing 3 gallon batches. It took about 3 hours to make the batch before letting it ferment for a few weeks. Over time I added on to the setup. I started fermenting in glass carboys. I started doing a secondary fermentation. It was all going well. (I was also able to add a few different pieces and also make wine. Incredibly easy.) I also went from 12 oz bottles to the flip top bottles (each bottle holds more and less bottles to clean).

As time progressed I met more people who brew and they were making beer the all-grain way. Then I came across a DVD on all-grain brewing. It actually looked easier than I imagined. I had a friend who did all-grain brewing (35 gallon batches) and he gave me his old coolers. I bought a false bottom, replaced some hoses, and did my first 5 gallon batch. Took about 6 hours to make but most of that time is sitting around and waiting. The beer came out awesome! I also started kegging into 5 gallon corney kegs instead of bottling. Tastes awesome. I made about 10 batches before I started looking at wanting to do bigger batches (actually 10 gallons). It takes the same amount of time and you get more.

Now I come to the main point of this whole bit of blabbing. I was looking at systems to do 10 gallon batches. After looking at the pre-built systems I decided that maybe I should try to build a system. I looked for plans and couldn't find anything that fit what I had in mind, kinda inexpensive. (BTW, there was an issue of Brew Your Own magazine that had a good article on building a brew system.) So I have decided to build a pump driven brew system. In my future posts I will try and posts pictures and show how I put the system together. I hope it helps someone else who decides to make their own system.

What I have purchased so far is 3 sanke kegs (from the salvage yard for a total of $75). Some fittings from Austin Homebrew Supply (Ball Valves, Bulkhead, Nipple). A false bottom from Midwest Supplies. A grain mill off of eBay (Barley Crusher Malt Mill pictured below).












I still need to purchase a counterflow wort cooler, a march pump, and get a sculpture to hold everything. Then I need to add burners and do the plumbing.

Hope you enjoy. More to come.