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Old 06-18-2012, 02:53 PM   #1
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Default 1BBL Stainless Single Tier

Ive been meaning to start this thread for some time now but havent gotten around to it until now. My brew partners and I started designing our second system recently. The stand was the first thing we needed. We currently brew on a 3 Keggle Herms system but do not have a dedicated stand. We decided that a nice stand was the building block for our new 1BBL setup. I came across a smoking deal on some SS 3" Angle Iron which we decided would be just what we needed to support our new 42G barrels that we ordered from Bubbas Barrels. In order to give our setup the desired bling we decided that it should be polished prior to all of the welding being done. Lucky for me I have a neighbor who is a welder and also happens to like home brew. This combo along with the great deal on the stand materials made this whole thing a little nicer on the pocketbook.

The pics show the original SS vs the polished and the stand as it began being welded. You can see the top and bottom welded up before the welds were cleaned up with the flap disc. The last pic shows what a difference the grinding makes in the finished look.

ss-angle-iron-being-polished.jpg   stand-matthews.jpg   stand-top-bottom-sections.jpg   weld-before-after-cleanup.jpg  
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Old 06-18-2012, 03:04 PM   #2
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With the stand on its way we placed our order from Bubba's Barrels. We decided on 42G Barrels for our system. We wanted to be able to still do 10G batches while also having the capability to do larger batches or bigger beers. We will mostly do 15-20G batches of our "goto" brews while still being able to easily do 10G batches for new beers. We will most likely also keep our Keggle setup for expirements and if we ever want to do smaller 5G batches. We ordered the Barrels and they arrived not to long after. As you can see by the photos these things are massive. They make the Keggles look tiny. We then placed our order for all of the fittings from Bargain Fittings. I spoke to Wayne and asked if they would custom cut a sight glass for me to 24" to fit the barrels and he agreed. He was very helpful and we highly recommend bargain fittings. They have always been great for us. With the fittings in hand we drilled the barrels and installed the fittings. We only had a small leak but tighted up the weldless fittings and they are now holding water without any issue. We decided to go with a sight glass on both BK and HLT and will be doing a side pickup in both as well. We drained and measured and we can pick up all but 1/2G from a 42G barrel. Success!!. We will whirlpool in the BK with a portable whirlpool attachment I made to fit the barrels from 3/8 SS tube I had.

barrels-size-comparison.jpg   barrel-vs-keggle-comparison.jpg   fittings-bargain-fittings.jpg   hlt-interior-fittings.jpg   holding-oxy-water-test.jpg  

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Old 06-18-2012, 03:18 PM   #3
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On my birthday I was having a big BBQ and my neighbor wheeled over my 90% finished stand as my bday present. WOW!! Thing is killer. We added 4 locking castors and are planning on beefing it up with 2 more in the middle to make sure there are no issues with the weight. As you can see it is a thing of beauty. It definitely has the BLING factor with the only non-stainless item being the copper immersion chiller/HEX coil. All connections are SS Cam-locks. I am currently looking into a stainless hex coil but still trying to decide if I want it permant and exactly how big it should be as it will need to be custom made. We are considering going to a plate chiller but still a lot of planning to go into the setup. My neighbor welded on a custom handle for the stand and it makes wheeling it around a breeze.

Attached are some pics of some different configurations. We originally only ordered 2 of the 42G barrels thinking that we might go with a 30G Mash Tun but after seeing the big boys on the stand we have decided we have to go for the 3rd 42G and finish this thing off right. As you can see in the last picture we are working on pump placement and need to get the burner mounts in place as well. Getting very close to taking this thing on its maiden voyage.

stand-keggle-setup-large-bk.jpg   42-fittings-installed.jpg   stand-complete-1.jpg   2-big-boys-one-keggle.jpg   pump-options.jpg  

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Old 06-18-2012, 04:34 PM   #4
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Whoa. Nice...I'm excited to see more!

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Old 06-18-2012, 05:50 PM   #5
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From experience with my 1 bbl rig, watch the heat exhaust coming off the burners. You will probably need to put a heat shield under you sight gauge.

Looks very nice. Yours is a bit higher than mine. These are ~56 gallon kettles

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Old 06-18-2012, 06:49 PM   #6
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Quote:
Originally Posted by br1dge View Post
We added 4 locking castors and are planning on beefing it up with 2 more in the middle to make sure there are no issues with the weight.
If those castors are bolted on, I would move them to the outside corners so they are under the upright. Where they are now, they're putting a lot of bending force on the horizontal pieces.
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Old 06-18-2012, 07:14 PM   #7
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Looks Great love the pump! Please be sure the inlet tothe pump is unrestricted...this could cause you probs


Quote:
Originally Posted by br1dge View Post
On my birthday I was having a big BBQ and my neighbor wheeled over my 90% finished stand as my bday present. WOW!! Thing is killer. We added 4 locking castors and are planning on beefing it up with 2 more in the middle to make sure there are no issues with the weight. As you can see it is a thing of beauty. It definitely has the BLING factor with the only non-stainless item being the copper immersion chiller/HEX coil. All connections are SS Cam-locks. I am currently looking into a stainless hex coil but still trying to decide if I want it permant and exactly how big it should be as it will need to be custom made. We are considering going to a plate chiller but still a lot of planning to go into the setup. My neighbor welded on a custom handle for the stand and it makes wheeling it around a breeze.

Attached are some pics of some different configurations. We originally only ordered 2 of the 42G barrels thinking that we might go with a 30G Mash Tun but after seeing the big boys on the stand we have decided we have to go for the 3rd 42G and finish this thing off right. As you can see in the last picture we are working on pump placement and need to get the burner mounts in place as well. Getting very close to taking this thing on its maiden voyage.
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Old 06-18-2012, 07:51 PM   #8
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Quote:
Originally Posted by BargainFittings View Post
From experience with my 1 bbl rig, watch the heat exhaust coming off the burners. You will probably need to put a heat shield under you sight gauge.

Looks very nice. Yours is a bit higher than mine. These are ~56 gallon kettles
Thanks Wayne. We are definitely considering the heat shield for the sight gauges. We were thinking that the 3" hangover from the angle iron might be enough protection but if not we will definitely be adding something in.

Thanks again for helping us out and cutting to the size we needed. Glad you get to see where some of your fittings ended up. Our stand is about 6" higher than the original plan was for. There was a slight miscommunication with my welder and it ended up being 6" taller than anticipated. Oh well. It seems that no matter how much you plan on these things there are always going to be a couple things that end up slightly different. Just happy to see the progress and finally feel like we are getting close to finishing her up. Thanks again Wayne

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Old 06-18-2012, 08:00 PM   #9
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Quote:
Originally Posted by bja View Post
If those castors are bolted on, I would move them to the outside corners so they are under the upright. Where they are now, they're putting a lot of bending force on the horizontal pieces.
The castors are actually welded on and you can see that we moved the left side further out already. I made the mistake of getting my welder drunk and then letting him go to town on it while he was hammered. Anyways, once we get the other two castors we are planning to put them in the middle and then test it out and adjust if needed. The steel angle iron that we used is rather thick (1/4" maybe) and I think we would most likely be good with just the 4 castors since we rarely plan on filling these babies up but better to be safe than sorry. I am going to put some water in them tonight while on the stand and see how it reacts.

Thanks for the input bja.
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Old 06-19-2012, 11:58 AM   #10
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We love our chugger pumps. The restricted side in the last pic is the output. Still trying to figure out exactly where the pumps will be mounted. I would have liked to mounted the chugger under the frame but I dont have enough clearance there to do so. Its looking like it will be just above the lower bar about the same level as my other pump. Would I have any issue with the input of the pump down as in the picture with a 90 degree elbow and camlock for the input?

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