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Here is the build.... https://www.homebrewtalk.com/showthread.php?t=293810

Highly recommend. I used extreme temp heat tape.

Been using the heatsticks for the last three batches. 30 mins to bring to rolling boil. Pull one to maintain or too much evap. Very easy.

Took 1 hour to bring approx 7 gallons to a boil from mashout. 1500 watt heatstick

Build proceeding. Valve on output to adjust to limit flow to hit temp target. About 21 ft of 1/2 inch copper pipe in the manifold.

Layout of the manifold in bottom of cooler. The output has a thermometer and valve to hit cooling temp. Need to put drain on bottom of cooler to drain warm water to keep ice in contact with manifold.

Picked up a 44qt cooler at year end sale. Should fit about 24 linear feet of 1/2 inch copper pipe. Cleanouts on the ends of each linear section. Photos of build coming.

Next step is the ice/water cooler. Copper manifold in an ice chest to save water.

Planning to recirculate to cool. The returns for the cooling whirlpool and the mashtun...

12x 13 + 3 inch feet stainless mesh basket in a 44 quart bayou stainless cooker in a 10 gallon gott cooler. To get the plastic top to fit, heat the threads on the top with a heat gun and press the top on.

DIY heat-stick. Better solutions exist, but I had the parts. High temp wire, high temp (Dow) food grade potting compound, High temp glass cloth electrical tape and GFCI shown in the photo. Note: There are risks with these, always test the GFCI and make sure to provide a margin to derate the...

Brewsticks in the lined cooler. Still a little room for the wort :-) . Might swap the DIY with the brewhardware solution.

Filled the Gott cooler with the 44 qt Bayou pot insert with 6 gallons of 71 degree water. Dropped in a 1500 Watt 110V brew stick with a 15AMP Compact Right angle Plug In GFCI (Leviton) and got the following rough heating profile. Ambient temp was 80 degrees. Went up 69 degrees in 60 minutes...

An initial fill with 5 gallons of 50 degrees water will reduce the required ice significantly. The trade off is time.

1 lb Ice to 1lb of 32 degree water requires 144 BTUs. Plan is to run roughly 10 ft 1/2 inch copper in bottom of cooler and throw ice on it. With losses might be roughly one to one, 5 gallons of ice for 5 gallons of 200 degrees wort. Parts on order.

Finally had to replace the plastic in the cooler.... major distortion. I put in a 44 quart stainless Bayou classic. Decided to do a Utah Bio Diesel stainless basket (12x13) to allow removal of the grains so 5 gallon boils using a 1500 watt heat stick to occur in the mash tun. Since I...

Did a similar build a few years back... still works really well. Putting a spring in the tube breaks up the flow and improves heat transfer. I clean in place, but the springs are also easy to remove. Don't forget the thermal fuses...

When the mash is circulating, the tubes remain roughly at the temp of the exiting liquid, and significantly lower that than the temp of the exiting liquid on the outside of the insulation (I can put my hand on the outside of the insulation for as long as I like). However, once the liquid...

Starting to move on this. To save some money, I decided to use a band heater (TEMPCO Band Heater, 1600Watts,13.3 amps with a layer of KFLEX insulation) with the existing RIMS heater for the copper. This is will be 2800 watts total, and I am putting it on two separate 20AMP GFCI 120V...

McMaster Carr, 4550T141 extreme temp heat tape gives 626 Watts on 120VAC (5.2 Amps) and costs $73.46 This link might be of use http://www.deltat.com/pdf/Quick%20estimates%20for%20wattage%20requirements.pdf The 500 watts should take 10 gallons up 1 degree every 3 three minutes. (if insulated...