I have a HERMS system similar to Kal's and love it. Did you check out his site?
http://theelectricbrewery.com/brew-day-step-by-step?page=6
I know you're not going electric but you could probably get a few good ideas.
Cheers!
Get two pumps! You'll be glad you did. I have a March 809 and a Chugger pump. I am very happy with both and haven't noticed a difference in output. The price of the Chugger was considerably less last time I checked.
For the sparge arm, IMO don't bother. Just keep the sparge water at least...
I've been using a Therminator for a few years now and love it now that I have all the bugs worked out of my system. I had the same problems with it getting clogged until I got a hop spider. I bought a stainless one from www.arborfab.com and love it. I didn't really care for the hop bag. Hop...
According to Chris White and Jamil Zainasheff in their Yeast book on p.138, "If the size of the starter is greater than 5 percent of the beer volume, let the yeast settle out first, then only pitch the yeast." I try to follow this but don't always have the time. I can say I've ever notice a...
Are the rivets and the screws in the hose clamps stainless steel as well? I've heard in the past that some stainless clamps do not have stainless screws which makes them undesirable in the BK. I may be wrong but stainless rivets take a hydraulic press and are not very common.