Did I put these bulk heads together wrong?

[electricd7]

Trying to get my keggle all ready for brewing this weekend. I just installed 2 weldless bulkheads from AIH one with a ball valve and the other with a thermometer. I drilled the holes just shy of 7/8" with a step bit and had to almost thread the bulk-heads into the holes. I installed the ball-valve side this way from the inside of the keg out: coupler -> large washer -> o-ring -> keggle wall -> large nut -> ball valve.

I installed the thermometer side like this (again from inside out): nut -> large washer -> o-ring -> keggle wall -> coupler -> thermometer.

I tightened it all down to the point that o-ring began to misshape under the washer and backed off just a tad. Filled it with about 7 gallons of water and both sides leaked! The ball valve feels a little loose from the outside, but I am not sure if its loose on the bulk head or if the nut is loose. Seems like there should have been a second o-ring for the outside of the keggle, but I don't think i could thread it on if it were there. What do I do? I attached a picture Thanks!

 

[BxBrewer]

Did you sand down "de burr" the inside after drilling the holes ? Your bulk head should be on the outside.

 

[electricd7]

No I didn't. Think that could be the issue?

 

[BxBrewer]

Good chance you cut the rovings when you tightened them up. Take them off and see if there is any slits/cuts on them. Feel the inside for any kind of burr.

 

[electricd7]

Excuse the "newness" but what are the rovings? Can that be fixed?

 

[BxBrewer]

Excuse the "newness" but what are the rovings? Can that be fixed?

Sorry, O rings. Your thermo looks fine. Your bulkhead for your ball valve should be turned around. So the nut and washer,o ring is on the inside like your thermo.

 

[J187]

http://www.bargainfittings.com/index.php?route=information/information&information_id=14

 

[electricd7]

Perfect. Thanks for the advice! I will give it another try this evening!

 

[electricd7]

Just an update...thanks for all the help. My kettle is now leak free. There were actually a few problems. I didn't debur and did slice one of the o-rings. I didn't have the bulk-heads together like the link J187 posted. I re-did it all and brewed last weekend and didn't lose a drop to a leak. Thanks again.