EarthBound

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I'm installing a heating element into my keggle, and I used a 1.25" conduit punch! The hole diameter is 1.6875". I'm not sure exactly what to do to fix this.

I was thinking of JBwelding the SS washer (1.5" ID, 2.25" OD) onto the kettle wall. The problem with that idea is that the washer is flat against the convex kettle wall. Maybe I should TIG weld the washer onto the kettle wall?

__________________
"You can do anything you set your mind to when you have vision, determination, and an endless supply of beer."

audger

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either get a 1.5" threaded coupling to weld in, which should have an O.D. close to 1.7", and then get a 1.5" to 1" reducing bushing to screw the element into, or you are going to have to weld in a plate and start over.

put the JB weld down and back away.

LandoLincoln

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Perhaps you could do some custom pounding onto the washer so it will match the curve of the pot.

Get a bean bag with a piece of leather laid on top of it and a pipe. Put the washer on the bean bag, put the pipe on the washer and then take a hammer and pound on the pipe until the washer bends a bit. Keep testing the curve to see if it matches.

EarthBound

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Good ideas, guys.

I should've mentioned that I'm doing this a la Kal's electric brewery. I've already built the conduit boxes, and one modification I made to them is that I'm adding 240VAC receptacles onto the back of the conduit boxes, where dryer cords will be plugged in to provide power to the elements.

I believe that a welded reducing coupling (1.5" to 1") would obstruct using the conduit boxes.

I think I should TIG weld a section of sheet metal over the hole on the outside of the keggle. I would then punch the correct size hole. Please let me know what you think of this.

__________________
"You can do anything you set your mind to when you have vision, determination, and an endless supply of beer."

sv_1

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Tig weld a stainless 1" nut on. Do you have male plugs going to the kettle?

Huaco

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So you are saying you will have "male" ends of 240V exposed? That is EXTREMELY dangerous. You don't want to have male hots sticking out just waiting to shock someone.

P-J

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That is a very bad idea. You will have 240V openly exposed on the cord plug prongs when it is disconnected.

Edit: Huaco,
You beat me to it.

EarthBound

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That is actually probably a better idea than the sheet metal! There would be a few little gaps to fill, but it's definitely feasible. I think it would still work with my conduit boxes, as well. We may have a winner...

I do not have male plugs. Why do you ask?

__________________
"You can do anything you set your mind to when you have vision, determination, and an endless supply of beer."

EarthBound

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You're right. I was trippin. Thank you.

Here's my new idea: The outlets will have their own weatherproof outlet box (with weatherproof outlet covers) over by the control panel. The dryer cords will be wired to the keggle conduit boxes. Does that sound good?

__________________
"You can do anything you set your mind to when you have vision, determination, and an endless supply of beer."

Huaco

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As long as your cord actually plugs INTO a receptacle. (Female) power supply.