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However, that is soft copper tubing, easy to gently bend it so that the connectors are located outside the kettle.

That compression fitting is definitely reducing your flow by a lot! What is your purpose for reducing it that much? You should probably leave it 1/2" for all of your fittings.

FEDERAL REGULATIONS http://www.ecfr.gov/cgi-bin/retrieveECFR?gp=1&SID=b42343493f26258d1eb8b9c1e9bac637&ty=HTML&h=L&n=27y1.0.1.1.20&r=PART#27:1.0.1.1.20.1 STATE REGULATIONS http://michigan.gov/documents/cis_lcc_brewdetail_57148_7.pdf PROBREWER.COM http://www.probrewer.com/resources/

I use either water boiled on the stove or even just my hottest tap water. My HLT isn't big enough to put in any more than my strike amount.

Yeah, that looks like what you're going to have to do with that fitting.

Are there threads on the outside of the bulkhead, inside the kettle?

I don't think anyone answered this for you yet. BIAB stands for Brew In A Bag.

Something like this? http://morebeer.com/products/universal-stopper-hole.html

The working part is brass "Place the brass nozzle with bead into the fluid container.". May want to de-lead it first. Don't know what the tubing is made of. May not be food-grade, may leach chemicals.

For just more than a buck less, you get 140CFM more (240CFM). 6" http://www.amazon.com/dp/B005KMTYFK/?tag=skimlinks_replacement-20

http://www.theelectricbrewery.com/ventilation "Electric based brewery: Divide the element size (in watts) by 17.6 to obtain the required CFM (cubic feet per minute). In our case we use a 5500W element in our boil kettle. 5500 / 17.6 = 312 CFM. We therefore require a fan that can move a...

For just under $30 more you can buy your own 24" x 24" sheet of the stuff from McMaster-Carr 9358T58. But then you'd have to cut it to 15" dia. yourself and use the scrap for something else. If you found a use for all of the scrap, you'd save about $0.22/sq-in.

No, $70 for just the screen: http://www.norcalbrewingsolutions.com/store/product496.html

http://www.norcalbrewingsolutions.com/store/False_Bottoms_Keg_Keggle.html

I thought he was going to say it came off and fell into his fresh batch of wort!

Or check out this thread for a calculator. https://www.homebrewtalk.com/f11/immersion-wort-chiller-calculator-376707/#post4720602

Yessir

Have you tried resetting it with everything unplugged?

That's like saying if you only have a 100W lamp plugged in, you should only have something like a 1 amp breaker. The breaker is sized for the wire it is protecting, not the appliance hooked up to it.

Excellent