Here is my build of a cooler mash tun. All in all, not that different that others before me, but maybe this will help answer questions for others.
My build is very similar to https://www.homebrewtalk.com/showthread.php?t=23008
I'm located in Alberta, Canada and I had trouble finding a couple items that I was looking for initially.
Parts
Important Notes
I'm not going to give step by step instructions at this point but rather I will post pictures and give notes on what I did.
The fender washer will not fit completely over the pipe nipple. I traced and cut out silicon washers to go over the pipe nipple, and between the cooler wall and fender washer. I used 4-5 silicon washers and after hand tightening - I had no leaks.
Here is the tighten down fittings inside the cooler
On the outside I only needed a single fender washer.
Rather than a hack saw, I used snips to remove the ends from the braided hose
Removal of the center hose is easier with two people. Think of a Chinese finger trap, while one person compresses the hose together, another can pull out the inner-hose. Then bend back the fraid ends.
Added the hose clamp and hex plug
Inserting end of needle nose pliers into the end of the braided hose, and opening them to stretch the end will help when adding the hex plug and putting the hose on the barbed fitting.
Everything attached inside
Finished!
My build is very similar to https://www.homebrewtalk.com/showthread.php?t=23008
I'm located in Alberta, Canada and I had trouble finding a couple items that I was looking for initially.
Parts
- 10 Gallon Orange Water Cooler (from Home Hardware: https://www.homehardware.ca/en/rec/.../No-24/Ntk-All_EN/R-I6456854?Ntt=cooler&Num=0)
- Brass Fittings
- Ball Valve
- Pipe Nipple
- Hex Plug
- female barb adapter
- male barb adapter
- Fender Washers
- Custom Silicon Washers
- Braided Stainless Steel Supply Hose
- Stainless Steel Hose Clamps
Important Notes
- Here, brass fittings are lead free unless you specifically buy ones that say they are not. I checked with a plumber friend. You will find some that don't specify on the package and some that say they are lead free.
- I had to go to several hardware stores to find the brass I needed. Home Depot and Lowes were OK. Rona was better and the contractor outlets might help too.
- Must use stainless steel, not copper, zinc, zinc coated, or other metal
- I could not find the right size stainless steel fender washers locally or off of a supply website that were not over priced. I ordered mine from ebay. If you are concerned that you are getting what you ordered, let one soak in vinegar.
- let a hose clamp soak in vinegar for a few days, while the clamp might be stainless steel, some of them contain a zinc-coated screw.
- Custom Silicon Washers were made from a silicon baking sheet
- Do not worry about the braided hose collapsing, it will still work if it did
- Do not prop/reinforce the braided hose with wire - many people do but not with stainless steel and the wort will eat the wire eventually. (hmmm, yummy).
- Transfer hose types. Pay attention to the type of hose you use for transferring the hot liqueur. Vinyl is not ideal for high temperatures. Silicon is a better choice I believe.
I'm not going to give step by step instructions at this point but rather I will post pictures and give notes on what I did.
The fender washer will not fit completely over the pipe nipple. I traced and cut out silicon washers to go over the pipe nipple, and between the cooler wall and fender washer. I used 4-5 silicon washers and after hand tightening - I had no leaks.
Here is the tighten down fittings inside the cooler
On the outside I only needed a single fender washer.
Rather than a hack saw, I used snips to remove the ends from the braided hose
Removal of the center hose is easier with two people. Think of a Chinese finger trap, while one person compresses the hose together, another can pull out the inner-hose. Then bend back the fraid ends.
Added the hose clamp and hex plug
Inserting end of needle nose pliers into the end of the braided hose, and opening them to stretch the end will help when adding the hex plug and putting the hose on the barbed fitting.
Everything attached inside
Finished!