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Old 12-16-2010, 02:16 PM   #1
Boerderij_Kabouter's Avatar
Dec 2007
Oconomowoc, Wisconsin
Posts: 7,750
Liked 148 Times on 120 Posts

I can't believe this thread doesn't exist. Let's put together a resource for people to see how they want to protect themselves for electrocution!

I'll go first...

My BK uses a rubber coated keg, so my situation may be a bit different.

It is a cannibalized plastic box with an all weather face plate. The recessed outlet is sealed up with silicone and the box is fully plastic welded (plastic specific epoxy) to the keg exterior.

I used a profile guage to steal the profile of the keg:

Then, I traced that profile onto the box, and cut it out with my mini band saw.

Then I clamped the box in place with a bungie cord, and epoxied the crap out of it. Wiped smooth with a squeegee and bob's yer uncle.

The flash picks up some extra epoxy, but it looks perfect with the naked eye.

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Old 12-16-2010, 02:34 PM   #2
Sep 2008
Gonzales, Louisiana
Posts: 964
Liked 19 Times on 17 Posts

You KNOW I'm ready to do mine, so I'll be watching this thread with interest.

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Old 12-16-2010, 03:06 PM   #3
ScubaSteve's Avatar
May 2007
New Bern, NC
Posts: 3,677
Liked 83 Times on 57 Posts

For my elements, I used 1" SLB conduit elbows, boring the hole a little larger with a step bit. Then I inserted the element, wired it up to include a strain relief at the bottom, and filled it with JB Weld. I let the epoxy cure overnight, not moving it until it hardened right where I wanted it. Then I screwed on the backplate and attached the ground wire to a lug I soldered on the kettle.

Just hope I don't burn out an's more work than I'd want to do every few brews, but it's rock solid and as safe as I could make it.
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Old 12-16-2010, 03:44 PM   #4
Dec 2006
hudson, wi
Posts: 707
Liked 39 Times on 33 Posts

Sorry for the link but I have never figured out how to post pics here.
Too make a long story short, I had 1/4" ss bolts welded to my kettles and then bolted on a waterproof outlet box. I drilled a hole in the back big enough to go over the electric element coupling and then used silicone caulking to seal up.

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Old 12-16-2010, 03:46 PM   #5
Diver165's Avatar
May 2010
Huntington, WVA
Posts: 524
Liked 11 Times on 9 Posts

Yes awesome thread. Im getting ready to go electric and I need tips and advice

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Old 12-16-2010, 08:43 PM   #6
hatfieldenator's Avatar
Sep 2010
Posts: 493
Liked 17 Times on 14 Posts

Here's mine. Its a custom Sabco HLT for my HERMS set up. They welded a half coupler for me for the heating element. I was able to simply drill a hole in the electrical box, insert the heating element, add the gasket it came with, and screw it into the half coupler. It made for a water tight seal without even using teflon. I will probably add high temp silicone in the box as well just to be safe.

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Old 12-16-2010, 11:51 PM   #7
trigger's Avatar
Aug 2010
Posts: 629
Liked 7 Times on 7 Posts

I did exactly what hatfieldenator did, but used a single gang box and soldered a 1" NPS locknut to the keg.

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Old 12-17-2010, 02:31 PM   #8
Boar Beer
Boar Beer's Avatar
Mar 2008
Central NH, NH
Posts: 530
Liked 18 Times on 15 Posts

Will send photos ASAP
I was married for 10 years before my wife knew I drank.
Then one day I made a mistake and came home from work sober

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Old 12-27-2010, 07:01 PM   #9
Yambor44's Avatar
Nov 2008
Ocala Florida
Posts: 2,108
Liked 84 Times on 56 Posts

With the exception of the OP, how do you clean your kettles with those wires permanently affixed?

I am getting ready to convert my system to electric, but want to be able to remove the wire from the pot for cleaning.

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Old 12-27-2010, 08:48 PM   #10
ScubaSteve's Avatar
May 2007
New Bern, NC
Posts: 3,677
Liked 83 Times on 57 Posts

I plan on CIP, but my element screws right out and my ground wire can be removed from the lug.

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