I know I know...another counterflow chiller. I'm hoping that mine shows a little more affordability than even some of the cheaper versions out there. There were few things that I wanted to do with this chiller
1. Not solder anything
2. Use as little expensive copper as possible
3. Use or re-use as many materials on hand as possible (cheap)
So that being said, here is my material list:
1. Used 5/8" garden hose with both ends in good condition $0.00
2. 20' 3/8" OD soft copper $25.86
3. A few inches of 1/2" CPVC $0.00 left over from mash manifold build
4. 2 CPVC 1/2" t's $.50
5. 2 CPVC 1/2" compression sleeves, not sure what these things are for but they have a hole in the center that is 3/8"...perfect $.50
6. 2 part Epoxy $3.50
7. CPVC glue $3.00
8. 4 stainless clamps $4.00
If I didn't have to by glue, this would have been dirt cheap.
The first thing I did was glue the compression sleeves into the cpvc t's.
Then added a couple short pieces of 1/2" cpvc stubs from the t's
I cut about 6" of hose off with the fittings and sleeved it right over the stub outs. It fit perfect.
Then I measured out about 19.5' of hose and cut that to sleeve the copper into.
Then started shoving the copper down the hose. This was way easier than I was anticipating.
Once that was done I secured one end of the copper to the fittings I built with the 2 part epoxy. Leaving about an inch and a half to slide hose over during transfers.
Slid the hose over the end of the fitting and clamped it down.
Now the fun part. I used a 2 or 2.5 gallon bucket to coil the hose around. I had my daughter stand on top of the bucket, shes roughly about 55 pounds, and I had my wife hold the beginning of the coil with her foot. I zip tied every 3 coils together on 3 sides all the way up. Overlapping ties.
Once it was all coiled up I measured how much hose I needed to cut off to get the correct amount of copper exposed before I installed the last fitting.
After I made the cut I slid the fitting over the copper and compressed the hose so that about 3" of copper was exposed. I coated the copper with epoxy and let the hose push it back into place, so that only an inch and a half was showing. And clamped it down.
Closer view, you can see the epoxy is pooled around the fitting well. Hopefully it won't leak.
And here it is completed. I left the plugs that the copper came with in place to protect it. Any reason I couldn't fill it with star san and store it that way with the caps on. How does copper react with that sanitizer?
I think the whole build would have cost about $30 if I didn't need to buy the glue and epoxy. I'll be brewing this week some time and I'll let you guys know if it leaks and how efficient it is.