so i had read through the several hundred pages of the solder stainless thread, and done a couple of vessels with 1/2" couplings for ball valves, thermometers, etc. now i wanted a heating element in my HLT to control my HERMS temps, so i dove in and made this happen!
for a primer on soldering stainless you may want to read this thread (or at least these few posts on how it all works). Big thanks to everyone who has done this before me, for giving me the courage to drill a 1.5" hole in a perfectly good HLT
i performed the same process except using a 1.5" hole saw, a 1" half coupler and a larger conical reducer.
coupling for electrical element: http://www.grainger.com/Grainger/SHA...Coupling-2UA77
reducer coupling to make dimple: http://www.grainger.com/Grainger/SHA...-Reducer-1RTW7
Drilled the hole in a keg lid to test
Assembled the Tool
Pulled the Conical Reducer through, checking every couple of turns for size
Got a great dimple, ready for the coupling
Pulled the coupling through till flush with inside
View from front