I found a site with some good advice but I have a stupid question. How is he holding the copper together? Do you just slide the pieces inside one another?http://www.zen77887.zen.co.uk/articl...tomashtun.html
Some people solder it together. I just push the pieces together and they stick. Whatever works for you.
Yes I think that is so that it can be broken down and cleaned easier.If you are going to batch sparge though you might consider a stainless steel braid from a water supply line. They work well. Another link> http://hbd.org/cascade/dennybrew/
I used this as a reference for my Igloo ice cube Mash tunhttp://www.howtobrew.com/appendices/appendixD-1.html
I think it gives a good breakdown of designing the tun and manifold.