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-   -   The Gator-ator! Build Thread. (Lots of Pictures) (http://www.homebrewtalk.com/f51/gator-ator-build-thread-lots-pictures-228373/)

Ciliorozo 02-27-2011 12:26 AM

The Gator-ator! Build Thread. (Lots of Pictures)
 
I have been meaning to pull a build thread together and after I had a few requests for one I decided to sit down and finally get it done. I will be posting a lot of photos. So without further ado here is my Jester Inspired Keezer. The Gator-ator!

A brief synopsis on materials used: The table top and the tap box are structurally 19/32 Plywood. Then we put a layer of Hardwood (Whitewood) over the tap box and on the trim. Then we finished the top with Granite tile. The tap box is anchored to the table top using t-nuts and bolts, then the table top is anchored to the freezer lid using t-nuts and bolts as well as liquid nails.

All straight cuts were done with a circular saw and all angled cuts with a miter saw.

Lets start with a look at the finished product:

http://www.homebrewtalk.com/gallery/.../DSC_03621.jpg

Here is where we started. My wife got me the greatest Birthday present a 3 Keg Kit! Plus a freezer and a bank of regulators.

http://www.homebrewtalk.com/gallery/data/9/P6171874.JPG

We then started with a single piece of 19/32 Plywood. In which we drew out the table top, plus the 4 sides to the tap box (Top, Left, Right, Front).

http://www.homebrewtalk.com/gallery/data/9/DSC_0194.JPG

Cheers! Here's my wonderful wife saying "Lets get this thing started!"

http://www.homebrewtalk.com/gallery/data/9/DSC_0197.JPG

Ciliorozo 02-27-2011 12:27 AM

We painted the freezer black using Black Appliance Epoxy

http://www.homebrewtalk.com/gallery/data/9/DSC_0220.JPG

For wood working, First we built the tap Box, basically a rectangle

http://www.homebrewtalk.com/gallery/data/9/DSC_0214.JPG

Here's what it looks like inside:

http://www.homebrewtalk.com/gallery/data/9/DSC_0215.JPG

We then added a 1"x4" strip to the front of the tap box (To give us the space to put the lights behind the taps), though we don't actually have a photo of this step. Onto this we put our hardwood Skin all around.

http://www.homebrewtalk.com/gallery/data/9/DSC_0528.JPG

From the back:

http://www.homebrewtalk.com/gallery/data/9/DSC_0530.JPG

Then we attached our trim to the table top using Heavy Duty Wood glue and clamps. The tap box is just sitting on the top right now, its not attached yet.

http://www.homebrewtalk.com/gallery/data/9/DSC_0527.JPG

Then we filled gaps with wood putty:

http://www.homebrewtalk.com/gallery/data/9/DSC_0543.JPG

We assembled the Dolly out of 2"x4" skeleton and then attached the 1"x4" Whitewood to the outside:

http://www.homebrewtalk.com/gallery/data/9/DSC_0538.JPG


Then we stained and sealed all pieces

http://www.homebrewtalk.com/gallery/data/9/DSC_0554.JPG

http://www.homebrewtalk.com/gallery/data/9/DSC_0348.jpg

Ciliorozo 02-27-2011 12:28 AM

Our wood was chosen based upon character! It watches you!

http://www.homebrewtalk.com/gallery/data/9/DSC_0560.JPG

Next we drilled Tap Holes using a 1" hole saw:

http://www.homebrewtalk.com/gallery/data/9/DSC_0841.JPG

Then we test fitted the Perlicks:

http://www.homebrewtalk.com/gallery/data/9/DSC_0855.JPG

Now that they fit we can install the lights and do the wiring. We installed 2 rope lights, a blue light and an orange light. We will attach them to a Dimmer in a later step.

First we fed them through a (previously cut) rectangle hole from inside the tap box. We then wired them to each other using our wire kit from circuits 1!

http://www.homebrewtalk.com/gallery/data/9/DSC_0946.JPG

Here they are with a test light:

http://www.homebrewtalk.com/gallery/data/9/DSC_0892.JPG

Next we embedded T-Nuts into the Lid. 4 from the bottom side so the tap box can anchor to them and 6 from the top side so that the freezer lid can anchor to them.

Here is a close up of one:

http://www.homebrewtalk.com/gallery/data/9/DSC_0859.JPG

Here is another shot, the 6 on top are to anchor to the freezer. There are 4 which you can't see embedded on the bottom for the tap box to anchor to.

http://www.homebrewtalk.com/gallery/data/9/DSC_0864.JPG

Next we removed the lid from the freezer and removed the insulation from the lid. Then jigged out 2 holes in the lid and applied duck tape:

http://www.homebrewtalk.com/gallery/data/9/DSC_0886.JPG

Then we applied liquid nails to the freezer lid and clamped and bolted the plywood top to it.

http://www.homebrewtalk.com/gallery/data/9/DSC_0891.JPG

Then we put the insulation back into the lid and cut the holes through the insulation and plastic liner.

The next step was freezer assembly. First the freezer went onto the dolly and then we attached the lid back to the freezer.

http://www.homebrewtalk.com/gallery/data/9/DSC_0927.JPG

Ciliorozo 02-27-2011 12:28 AM

Next we attached the tap box and shanks

http://www.homebrewtalk.com/gallery/data/9/DSC_0939.JPG

Then we added multiple layers of foam insulation. Here is the layer with the beer line channel carved out (This foam was reused form a fermentation chamber in which I glued a few pieces of the foam together, thats why you can see brown glue traces).

http://www.homebrewtalk.com/gallery/data/9/DSC_0940.JPG

Then here is what the last layer looked like. There is a hole cut out for the Dimmer. But this is pretty tight and when the back is screwed on it will be a tight compression fit.

http://www.homebrewtalk.com/gallery/data/9/DSC_0948.JPG

Next we marked up the Granite and took it to Lowe's to get it cut. (Took us 3 trips to get all pieces to fit)

http://www.homebrewtalk.com/gallery/data/9/DSC_0955.JPG

Then we glued the granite using liquid nails, silicone caulked it (used silicone since it was going to be on a moving surface we didn't want it to crack), and then sealed it. Here are a few photos:

http://www.homebrewtalk.com/gallery/.../DSC_00294.JPG

http://www.homebrewtalk.com/gallery/.../DSC_00313.JPG

Ciliorozo 02-27-2011 12:29 AM

While the granite was being cut we did the plumbing. First we JB welded 2 cabinet door hinges into the freezer body to hold the regulator bank. We then zip tied the regulator bank to these hinges.

http://www.homebrewtalk.com/gallery/data/9/DSC_0907.JPG

Test fit, we can hold 3 kegs on tap plus carb one in waiting.

http://www.homebrewtalk.com/gallery/data/9/DSC_0934.JPG

Here is a view of the plumbing on the inside:

http://www.homebrewtalk.com/gallery/data/9/DSC_0952.JPG

Next we wired the dimmer switch. We cut the plug end off of the cord that connects to the rope lights and attached that end to the dimmer. Then we cut off an extension cord female end and wired to the dimmer so that we can use this cord to plug into the wall. Here is what it looks like:

http://www.homebrewtalk.com/gallery/data/9/DSC_0945.JPG

Then we added the faucets, drip tray, Gator stickers, Bar Mats, and Pint Glasses to finish it up.

http://www.homebrewtalk.com/gallery/.../DSC_01811.JPG

Ciliorozo 02-27-2011 12:29 AM

Here is the first Pint: (This was actually before we caulked the tile. So there is a noticeable line in the back splash granite.)

http://www.homebrewtalk.com/gallery/.../DSC_00027.JPG

And the first pint in the Orange and Blue:

http://www.homebrewtalk.com/gallery/.../DSC_00095.JPG

The Gator-ator in the Orange and Blue

http://www.homebrewtalk.com/gallery/data/9/DSC_0984.jpg

Ciliorozo 02-27-2011 01:52 AM

And to complete the Jester Clone. Here are some extra photo scenes made famous by Jester and Red.

http://www.homebrewtalk.com/gallery/data/9/DSC_0179.JPG


http://www.homebrewtalk.com/gallery/.../DSC_02461.JPG


Man, after writing this thread it kind of makes building one of these look easy. It actually took about 5 months to really get started on the project and then about another 2 months to finish it.

tmurph6 02-27-2011 02:05 AM

You ruined it with all the Florida crap. Geaux Tigers!!

Bizoune 02-27-2011 02:25 AM

Great build! Congrats...

coypoo 02-27-2011 02:39 AM

Go Gators! Love the Fightin' Gator on top, he's a bada$$


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