Ok so it looks like i get to have double the fun starting VERY soon. To recap, my plan of action was going to be: build a smaller brewery (2-3gal) and brew numerous "test" batches. I put my original brewery in storage (under my stairs) and just recently started working on my newer smaller brewery (pictures below). I was going to do this since i wanted to try more recipes more frequently and since i like to build stuff, lol.
Things have changed though. It seems like my new boss and co-workers are pretty pumped that i brew beer and want to participate. So the new plan of action is such: I will take my "old" brewery out from under the stairs and move it to my coworkers shop (he has a workshop on his property which is about 20ft x 50ft. The shop has 240V connections throughout and has an unused paint room (never actually used to paint) in the back which will now be the Brewhouse (i'm thinking of naming it "Goat River Brewing", label design to follow). So i have a couple thing i need to fix on the "old" system and i have just designed and purchased parts for what will be a "conical" sanke fermenter. Conical is in brackets since it wont actually be conical, i debated getting some sheets of SS and cutting, rolling and welding it to the bottom of a keg i have, but i neither have the skill nor tools to do this so i came up with a variation of a design which i found here (pictures will be posted when i start work on it, soon).
The only issue is i will have to transport my control panel and pump between brew locations since i still want to brew at my new place with the new system i am making. But to be honest this is the least of my concerns, lol.
ok and now for some progress on the new system:
I was able to clean and cut open the keg for my kettle (using a 1/4 barrel keg). i bought a punch set from harbour freight thinking that it would be nice to use this to cut holes instead of using the step bits i have. But i ran into 2 problems, when i used the 1/2 punch it broke the bolt in 1/2 (crud!) so i finished the hole with the step bit anyways. I then figured i would try the 1" punch for the hole for my element since it had a MUCH thicker bolt. Well this time it worked, but to my shock the hole it cut was like 3/16" too big for the element. Luckily i was able to find a work around and used a silicone gasket and washer to seal the element tight enough to prevent leaking.
Once this was done i moved onto building my mash tun. I have 2 1/4 barrel kegs which have the plastic top and bottom (similar to a corny). Lets just say cutting through the plastic has been my BIGGEST pain the the arse since i started building/brewing. But i figured out a way to do it at low speed with a dremel (this way i didnt have blue plastic dust flying everywhere). I was then able to cut a hole in the top using my grinder (i find doing so freehand works the best, no need for jigs). Same as before i used a step bit to drill the hole for the valve (i still need to add my thermometer to the MT).
Ok thats enough writing for now. Pictures posted in the next post