Home Brew Forums > Home Brewing Beer > DIY Projects > Kettles, Mash Tuns, & Hot Liquor Tanks > One Jig to Cut Kegs and False Bottoms
Reply
 
Thread Tools
Old 03-21-2011, 04:12 AM   #1
dutchoven
HBT_SUPPORTER.png
Feedback Score: 0 reviews
 
dutchoven's Avatar
Recipes 
 
Join Date: Mar 2011
Location: SF Bay Area, California
Posts: 641
Liked 8 Times on 8 Posts
Likes Given: 4

Default One Jig to Cut Kegs and False Bottoms

Im in the process of moving to all-grain and have been fabbing up a new brew kettle, MLT, and HLT from kegs. I recently cut my kegs and built a custom false bottom thought Id post my progress so far.

First, the keg cutting

To cut the kegs, I built a jig out of 1x2 wood stock and fit it to a 4 angle grinder. The jig mounts to the grinder handle attachments and pivots off the keg opening. All told, the jig took me about 45 minutes to build and cost around seven bucks. Yeah, probably overkill, but it helped me get really nice cuts

Click image for larger version

Name:	IMAG0188 2.jpg
Views:	1497
Size:	26.5 KB
ID:	22168

In building the jig, I wanted something that could be adjusted to different cutting diameters. To do this, I let the pivot point of the jig float in the jig, adjusted by a bolt installed in the back of the jig. Once I set my desired diameter (12 for the keg openings), I screwed everything into place.

Click image for larger version

Name:	IMAG0353.jpg
Views:	1492
Size:	24.7 KB
ID:	22169

At the pivot point, I used another bolt to adjust the height of the jig and angle of the blade this helped maintain the cut-off wheel at 90 degrees to the keg top.

Click image for larger version

Name:	IMAG0354.jpg
Views:	1505
Size:	32.7 KB
ID:	22170


dutchoven is offline
 
Reply With Quote
Old 03-21-2011, 04:14 AM   #2
dutchoven
HBT_SUPPORTER.png
Feedback Score: 0 reviews
 
dutchoven's Avatar
Recipes 
 
Join Date: Mar 2011
Location: SF Bay Area, California
Posts: 641
Liked 8 Times on 8 Posts
Likes Given: 4

Default

The jig pivots on a 2 diameter block built from two stacked plywood circles cut with a 2-1/8 hole saw. This conveniently left me with a 2 diameter block with a 1/4" hole in the center fits perfectly in the sanke keg opening. The height adjustment screw on the jig fits into the 1/4" hole.

Click image for larger version

Name:	IMAG0182.jpg
Views:	1467
Size:	21.8 KB
ID:	22171

Click image for larger version

Name:	IMAG0183.jpg
Views:	1494
Size:	19.6 KB
ID:	22172

Prior to cutting, I depressurized the keg and removed the dip tube. I then filled the keg with water to dampen the noise and remove excess heat. During the cut, I took several passes; removing a little material at a time this resulted in a cleaner, perfectly round cut.

Click image for larger version

Name:	IMAG0212 2.jpg
Views:	1483
Size:	34.8 KB
ID:	22173


dutchoven is offline
 
Reply With Quote
Old 03-21-2011, 04:16 AM   #3
dutchoven
HBT_SUPPORTER.png
Feedback Score: 0 reviews
 
dutchoven's Avatar
Recipes 
 
Join Date: Mar 2011
Location: SF Bay Area, California
Posts: 641
Liked 8 Times on 8 Posts
Likes Given: 4

Default

On my first keg, I used a Harbor Freight cut off-wheel, which cut fine. On the other kegs, I used a Dewalt XP cut-off wheel. The Dewalt cut faster and left me with a cleaner cut well worth the extra cost.

Once the kegs were cut, I deburred with a flapper wheel. Before

Click image for larger version

Name:	IMAG0205.jpg
Views:	1443
Size:	24.7 KB
ID:	22174

After

Click image for larger version

Name:	IMAG0227.jpg
Views:	1440
Size:	17.9 KB
ID:	22175

Click image for larger version

Name:	IMAG0230.jpg
Views:	1449
Size:	25.9 KB
ID:	22176

Overall, cutting the kegs went way better than expected. I couldn't imagine trying to cut a keg "freehand".
dutchoven is offline
 
Reply With Quote
Old 03-21-2011, 04:23 AM   #4
dutchoven
HBT_SUPPORTER.png
Feedback Score: 0 reviews
 
dutchoven's Avatar
Recipes 
 
Join Date: Mar 2011
Location: SF Bay Area, California
Posts: 641
Liked 8 Times on 8 Posts
Likes Given: 4

Default

Now for the False Bottom …

I wanted a full-size false bottom (15 1/8” in my case) so no grain would sit on the floor of the MLT. I settled on a two-piece design that could be bolted together inside the MLT. To fit the false bottom through the 12" opening in my keg, I cut one piece at 12" wide; the other piece accounts for the remaining 3 1/8". I chose to offset the seam to maintain the overall strength of the FB.

Click image for larger version

Name:	IMAG0363.jpg
Views:	1442
Size:	59.8 KB
ID:	22177

Click image for larger version

Name:	IMAG0374.jpg
Views:	1450
Size:	172.5 KB
ID:	22178

The FB is built out of 16-gauge stainless with 3/32” perforations on 5/32” centers. I picked up the perforated at a local metal company (Howard Wire Cloth in Hayward, CA). A 12” x 48” sheet ran me $66 (about 20% cheaper than onlinemetals.com).

To cut the FB, I drilled a hole in what would become the center of my FB for the pivot point of my jig.

Click image for larger version

Name:	IMAG0300.jpg
Views:	1457
Size:	40.5 KB
ID:	22179
dutchoven is offline
 
Reply With Quote
Old 03-21-2011, 04:26 AM   #5
dutchoven
HBT_SUPPORTER.png
Feedback Score: 0 reviews
 
dutchoven's Avatar
Recipes 
 
Join Date: Mar 2011
Location: SF Bay Area, California
Posts: 641
Liked 8 Times on 8 Posts
Likes Given: 4

Default

I set my jig to 15 1/8 and went to town, cutting the larger section first. I nailed the perforated sheet to my work surface to keep it from moving around.

Click image for larger version

Name:	IMAG0313 2.jpg
Views:	1433
Size:	52.4 KB
ID:	22180

Click image for larger version

Name:	IMAG0317.jpg
Views:	1429
Size:	70.0 KB
ID:	22181
dutchoven is offline
 
Reply With Quote
Old 03-21-2011, 04:30 AM   #6
dutchoven
HBT_SUPPORTER.png
Feedback Score: 0 reviews
 
dutchoven's Avatar
Recipes 
 
Join Date: Mar 2011
Location: SF Bay Area, California
Posts: 641
Liked 8 Times on 8 Posts
Likes Given: 4

Default

After cutting the larger section, I ground the edge straight, matched it back to the perforated sheet, and cut the smaller section.

Click image for larger version

Name:	IMAG0332.jpg
Views:	1424
Size:	39.1 KB
ID:	22182

Click image for larger version

Name:	IMAG0336.jpg
Views:	1409
Size:	30.7 KB
ID:	22183

Apparently, I like to wear striped thremals when I use an angle grinder

Click image for larger version

Name:	IMAG0344.jpg
Views:	1412
Size:	31.9 KB
ID:	22184
dutchoven is offline
 
Reply With Quote
Old 03-21-2011, 04:36 AM   #7
dutchoven
HBT_SUPPORTER.png
Feedback Score: 0 reviews
 
dutchoven's Avatar
Recipes 
 
Join Date: Mar 2011
Location: SF Bay Area, California
Posts: 641
Liked 8 Times on 8 Posts
Likes Given: 4

Default

To connect the two sections, I cut down a 1 wide strip of perforated and fit it to the bottom of the two sections.

Click image for larger version

Name:	IMAG0356.jpg
Views:	1397
Size:	45.4 KB
ID:	22185

Drilled out for #6 by 3/8 SS bolts to hold the whole thing together.

Click image for larger version

Name:	IMAG0367.jpg
Views:	1392
Size:	40.0 KB
ID:	22187

Click image for larger version

Name:	IMAG0366.jpg
Views:	1378
Size:	43.8 KB
ID:	22186

Click image for larger version

Name:	IMAG0376.jpg
Views:	1376
Size:	42.3 KB
ID:	22188

After everything was cut, I deburred with the flapper wheel.

Overall, Im very happy with the FB. It fits tight in the MLT and sits approximately two inches from the bottom center (should allow for direct fire RIMS).
dutchoven is offline
 
Reply With Quote
Old 03-21-2011, 04:44 AM   #8
drkered
Feedback Score: 0 reviews
Recipes 
 
Join Date: Apr 2010
Location: Edmonds, WA, Wa
Posts: 15
Default

Very professional looking sounds like you were able to make it pretty cheap too.
drkered is offline
 
Reply With Quote
Old 03-21-2011, 04:53 AM   #9
Ceedubya
Feedback Score: 0 reviews
Recipes 
 
Join Date: Aug 2008
Location: Helena, MT
Posts: 1,515
Liked 11 Times on 11 Posts
Likes Given: 11

Default

ONE JIG TO CUT THEM ALL!

Nice work, I have one last keg to cut, will be using this!
__________________
Hey, careful, man, there's a beverage here! - The Dude

I don't understand the purpose of the line, "I don't need to drink to
have fun." Great, no one does. But why start a fire with flint and
sticks when they've invented the lighter?
Ceedubya is offline
 
Reply With Quote
Old 03-21-2011, 12:41 PM   #10
Seven
Feedback Score: 0 reviews
Recipes 
 
Join Date: Jan 2011
Location: Pittsburgh, PA
Posts: 1,540
Liked 156 Times on 79 Posts
Likes Given: 112

Default

Nice work!


Seven is offline
 
Reply With Quote
Reply


Thread Tools


Similar Threads
Thread Thread Starter Forum Replies Last Post
Cut keg top for false bottom? benbradford Kettles, Mash Tuns, & Hot Liquor Tanks 108 09-29-2012 03:57 PM
$12 false bottom randyisrad Kettles, Mash Tuns, & Hot Liquor Tanks 9 12-19-2010 08:03 AM
Blackening Kettle Bottoms ChemE Kettles, Mash Tuns, & Hot Liquor Tanks 123 09-17-2010 10:34 PM
False bottom pipapat Kettles, Mash Tuns, & Hot Liquor Tanks 4 06-28-2010 11:37 AM
False Bottoms, Diptubes, Bazookas Oh My! TriangleIL Kettles, Mash Tuns, & Hot Liquor Tanks 3 06-14-2010 10:35 AM


Forum Jump

Newest Threads

LATEST SPONSOR DEALS