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Just to confirm... is this cooler size good for 5 gallon batches? I'm just brewing normal beer, no fancy stuff. Would a smaller cooler be a better fit? It just seems like the grain bed would not be very thick.

Great! I'm glad to hear this is somewhat normal and the siphon effect makes sense. With a 3/4" gap between the bottom of the outflow and bottom of the cooler, (working backwards here) I'll plan to direct the copper tube from the outflow at a slight downward angle meet the manifold somewhere in...

I have a 52 quart rectangular Igloo cooler that I'd like to use to make my first mash tun. The inside dimensions are 21"x11" and I'll be making 5 gallon batches with room to expand to 10 gallon batches. Here's my concern: The bottom of the cooler is flat and the outflow hole is 3/4"...