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Old 08-06-2012, 05:29 PM   #211
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Default New Mash Tun - Converted 40 Gallon Market Forge Direct Steam Tilit Kettle

This is the false bottom. I used silicone hose around the parameter to help keep it in position and create a tighter fit. I used a piece of stainless mig wire to tie the hose to the false bottom. I have 2.5 galons of dead space below the false bottom.

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Old 08-06-2012, 05:38 PM   #212
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Default New Mash Tun - Converted 40 Gallon Market Forge Direct Steam Tilit Kettle

While my friend was cutting the false bottom on the plasma table I fabbed up stainless side and back panels and new inner door skins seen here. You can also see the 1.5” valve assembly sitting on top waiting to be TIG welded in. I also welded 5" heavy duty casters in place of the legs so I can move it in and out of position while brewing.

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Old 08-06-2012, 05:45 PM   #213
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Default New Mash Tun - Converted 40 Gallon Market Forge Direct Steam Tilit Kettle

Here is a shot of the ferrule before I TIG welded it on the dump outlet. I had to heat and remove the brass T that was on the kettle when I received it. The dump outlet and Tri-Clamp ferrule were the exact diameter and thickness so no filler wire was needed, I just fused them together. Probably not good for a pressure connection but plenty strong enough for a drain. I kept the heat down and gassed the inside while welding and got a good clean weld with one pass.

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Old 08-06-2012, 05:50 PM   #214
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Default New Mash Tun - Converted 40 Gallon Market Forge Direct Steam Tilit Kettle

Here are a few shots of the fitted connections including the jacket in/out, lid return and the dump valve assembly. You can also see the casters I added in the dump valve shot.

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Old 08-06-2012, 06:16 PM   #215
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Default New Mash Tun - Converted 40 Gallon Market Forge Direct Steam Tilit Kettle

Needed a way to measure volumes so I filled the kettle gallon by gallon and marked the kettle wall with pencil. Then I transferred the marks to a couple stainless strips I formed to fit in kettle. Eventually I will attach the strips to the false bottom to assure it stays in place.

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Old 08-06-2012, 07:44 PM   #216
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AMAZING!
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Primary 1: Air
Primary 2: Air
Secondary 1: Blueberry pinot noir
Secondary 2: Air
Kegged: Rye Pumpkin Saison, HopFingers, Simple Saison
Bottled: Peanut butter banana porter
On Deck: Pliny the Zombie, Rye IPA, Passion Fruit IPA, 100% Brett IPA
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Old 08-06-2012, 08:29 PM   #217
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Default New Mash Tun - Converted 40 Gallon Market Forge Direct Steam Tilit Kettle

Brewed my house favorite 444 Triple Lager (AKA - Triple Fo).

The grain bill was just over 58 lbs for a 1.044 gravity beer. Used a plastic tub to crush into and weighed with a large postal scale.


Notice – I brew barefoot and topless. Viewer discretion advised.

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Old 08-06-2012, 08:48 PM   #218
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Default New Mash Tun - Converted 40 Gallon Market Forge Direct Steam Tilit Kettle

In my previous configurations I added the grain to the mash tun, heated water in boil kettle, pump strike water into the bottom of the mash tun and stir. I have that process dialed in with the help and tweaking of Beersmith. With this set setup I decided to switch up and heat the mash tun jacket, heat strike water in HLT and keggle BK then transfer to mash tun and add grain. According to Beersmith to hit my target mash temp of 154* I needed to heat the mash tun and strike water to 161*(I used the BIAB single infusion in Beersmith). With the use of the Rinnai tank-less hot water heater I was able to dial in the water temp entering the keggle BK and HLT and used their perspective burners to temper the last few degrees. Basically strike and sparge on demand.

Here's a few shots heating strike water and transfering with the mash tun in its brewing position. (sorry about the blury photo's)

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Old 08-06-2012, 09:02 PM   #219
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Default New Mash Tun - Converted 40 Gallon Market Forge Direct Steam Tilit Kettle

Dough in and stir.

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Old 08-06-2012, 09:12 PM   #220
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Default New Mash Tun - Converted 40 Gallon Market Forge Direct Steam Tilit Kettle

I made an extension cord for my temp probes (sitting behind mash tun) and utilized the same mash tun input position on the brewstation. I monitor the temp of the mash tun jacket, wort leaving the HERMS and wort leaving the mash tun. I verified temps in the grain bed and with the heated jacket there was little to no stratification.

Here are a few shots during mash recirculation.

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