Thought I would share how I built the bulkhead on my Coleman Xtreme. All parts were purchased from Lowes. Credit goes to Bobby_M for inspiration from his design here.
1/2" NPT Coupler
3/4" SS Washer (had to be dremeled slightly larger to fit over nipple)
2" NPT Nipple
3/4" Alloy Washer (cheaper than SS and fit over nipple without modifying)
1/2" Ball Valve
1" CPVC Coupler (1" to 1" female)
For a washer/oring I used the existing white rubber washer that originally sealed the outlet fitting (can be seen in the picks below).
Here is the cooler, and the parts used.
The one part I forgot to show (but shown below) was the 1" CPVC coupler I used as a spacer in the cooler wall. Also, I ended up using an alloy washer on the outside because it was thicker than the SS one.
Closeup of the assembled parts
Getting ready to dremel out a hole that the 1" CPVC spacer will fit into.
I used a chop saw to cut the 1" CPVC spacer to the right height (just flush with the outside of the cooler). The spacer prevents the thick (foam filled) wall from collapsing when you tighten the bulkhead.
I had to notch the SS washer because the factory hole Coleman drilled was not centered. The notch prevented the washer from resting on the curved side.
This needs to be stickied! I searched for a solution to my bulkhead sealing issue and when I found this thread the lightbulb in my engineering brain clicked ON.
It's so simple! The reason for bulkhead fittings leaking is because the bulkhead is filled with soft foam. the moment you try to compress your gaskets into the weak bulkhead it compresses and does not provide a tight seal. The PVC spacer IS the solution! Thank you.
I just used a 3/4" sch40 PVC coupling trimmed to the right thickness as a spacer and was able to crank down on the bulkhead nice and tight! 7 gallons of water in the cooler for 2 hours and not a leak and not a drop of water made it into the dry foam insulation between the two walls! I'm going to seal my exposed foam insulation with silicone just in case a leak develops down the road...that way I'll get wort leaking out instead of leaking into the insulation!
Next up: American Pale Ale
Primary 1&2: American Brown Ale
Primary 3&4: Hopped up Belgian Tripel
Bottle Conditioning/drinking: Summer Kolsch, White Zombie (Amarillo IPA), English Pale Ale (ESB)
I used a CPVC coupler to attach to the nipple right up against the Colemans stock gasket. This allows an easy connection to my cpvc manifold. Used Zinc plated washers on the OUTSIDE of the cooler to make it tight and fill the space of the nipple to the ball valve...no leaks for 2 years.
Yours is def a more solid build. Just saying if you don't want to mod the cooler (mine can have the factory stuff reinstalled if need be