I've been looking for a way to build a 240 volt heatstick for the boil kettle in my eherms rig. I wanted it to have a replaceable element so this is what I came up with. It's made mostly from parts from StPats and a couple from Mcmaster.
2 - 2" weld on ferrules, $8 ea.
2 - 2" silicone gaskets, $1.50 ea.
2 - 2" tri-clamps, $7.50 ea.
2 - 2" end caps, $5 ea.
1 - 316 stainless elbow ½" $6.10
1 - ½" ss pipe, 18" long $18.65
1 - alum cord connector $6.44
1 - 5500 watt ripp element, $18
The two ferrules are welded together , drilled a hole in the top and welded on the 18" pipe. The hardest part was drilling and tapping the end cap to thread the element into. We were able to chuck it into my friends big metal lathe. He just happened to have a 1 5/32" bit which is the exact size needed for a 1" NPT tap. I have a few more things to do to finish it up, wire it of course, weld on a small bolt inside for the ground wire.