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Old 10-23-2009, 02:13 PM   #21
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Nice simple solution, but I second Bobby's point. That whole thing will fall through with the lid.

Doesn't anyone just freehand? I freehanded mine and got a very smooth circle. I guess if you're cutting out a ton this may take longer, but I like the feeling of free hand work.

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Old 10-23-2009, 02:21 PM   #22
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Nice simple solution, but I second Bobby's point. That whole thing will fall through with the lid.

Doesn't anyone just freehand? I freehanded mine and got a very smooth circle. I guess if you're cutting out a ton this may take longer, but I like the feeling of free hand work.
I freehanded mine...with a battery powered recip saw, (was surprised at the oomph this thing has....it's a WORX I got off of Woot for 40 bucks.).

I have one "non-circular" bit from when I first started with a regular blade and realized I couldn't make it turn the corner....putting in a carbide grit blade allowed for a smooth circle for the rest though.


SUPER cool jig you made there though passedpawn! I like the simplicity!
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Old 10-23-2009, 02:23 PM   #23
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Nice simple solution, but I second Bobby's point. That whole thing will fall through with the lid.
4 times. No problem. At all.

Extend the pipe 20" (or so) so that it is just off the bottom of the keg. That should allay any concerns of plummeting power tools.
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Last edited by passedpawn; 10-23-2009 at 05:20 PM. Reason: Added the "Extend the pipe" idea... just came to me!
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Old 10-23-2009, 02:25 PM   #24
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Originally Posted by IrregularPulse View Post
Nice simple solution, but I second Bobby's point. That whole thing will fall through with the lid.

Doesn't anyone just freehand? I freehanded mine and got a very smooth circle. I guess if you're cutting out a ton this may take longer, but I like the feeling of free hand work.
If you're cutting more than one keg and actually want to use the tops for lids again, you'd want them to all be exactly the same size circle. That's the real benefit of a jig.
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Old 10-23-2009, 03:58 PM   #25
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Nice jig indeed !

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Old 10-23-2009, 04:50 PM   #26
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I decided to try the crappy jig that I made last night rather than build this. It worked out ok but this design would have saved me a lot of time in building the jig.

I don't mean to thread jack but I have a quick question as I just my keggle top 10 minutes ago. Is it ok to use a hand file to clean up the cut? I would assume it is but I don't know if this will cause rusting in the future.

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Old 10-23-2009, 06:17 PM   #27
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I hit mine quickly with a file, and then some sand paper.

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Old 10-23-2009, 06:36 PM   #28
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I used a dremel with a grinding bit and then sandpaper...worked great.

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Old 10-23-2009, 06:52 PM   #29
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I hit mine quickly with a file, and then some sand paper.
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I used a dremel with a grinding bit and then sandpaper...worked great.
Thanks guys. I just finished it up with the file and then sandpaper. Worked great and a perfect circle. Also, built my Lil Sparky type hop bag so I'm ready to go for Sunday. A little brew while watching the Steelers kick the Vikings faces in!
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Old 10-23-2009, 07:04 PM   #30
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unless you are doing a lot of kegs, I dont see why you would need a jig?

A string with a loop tied in it to fit over the couplers center well.

A tape measure to make a mark on the string for diameter, and a black magic marker to mark the sting and draw the circle on the keg.

The kegs rim and the back of your hand makes for a perfect guide for going around the mark lightly scoring it the first time around with the grinder.

After that the score mark and the rim keeps the grinding wheel in place.

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