Best tool for making largest possible opening in keggle

[markstache]

I've got a rather large immersion chiller at 14" diameter. For a keggle conversion, between angle grinder and dremel, what tool would work best for getting a sufficiently large opening? I'm leaning toward using my dremel as I think I could get the smaller wheels closer to the lip of the keg. I know it will take longer, but speed is not my primary concern; fitting my immersion chiller is.

 

[sandyeggoxj]

I would go plasma. Nice and clean and will get way out there.

 

[Transamguy77]

I used a cut off wheel and used like 10 disks, if you used a dremel I would imagine you will use a lot of cut off tools too. That stainless is hard and pretty thick. If I had to do it again I would use an angle grinder. Oh and fill the keg full of water, it will cut down on the noise while cutting.

 

[user 125772]

Couldn't you just wind the immersion chiller a little tighter to reduce the diameter?

 

[Stillraining]

i would go plasma. Nice and clean and will get way out there.

+1

 

[jschm19]

Used a plasma cutter for all 3 of mine. They all turned out awesome and clean.

 

[jschm19]

Where are you located? If you are in Michigan I might be able to hook you up.

 

[markstache]

Couldn't you just wind the immersion chiller a little tighter to reduce the diameter?

Not really. It is 5/8" AC line copper. Even getting the radius that I got was a PITA. (Not to mention finding the right sized fittings.) However, I rechecked the dimensions and it is closer to 13" than 14".

Thanks for the reminder of plasma cutting. I'll look into it.

I used a cut off wheel and used like 10 disks, if you used a dremel I would imagine you will use a lot of cut off tools too.

I've heard people say it takes about 5 of the 1.5" metal cutting disks. So the costs would probably be comparable to buying an angle grinder and disks (given I already have the dremel).

Where are you located? If you are in Michigan I might be able to hook you up.

I'm in Illinois, but thanks for the offer.

 

[dmcman73]

I read about a few users that used a dremel and it took way to long and they went through a lot of cut off wheels.

I used an angle grinder tool and I was able to only use 1 disk and I built a jig for the angle grinder to keep it centered. I did a series of cuts, each time going deeper with each pass. I didn't jam the angle grinder into the SS which is probably why others have gone thorough a lot more disks then I have. Once I cut through, I used a sanding disk on the angle grinder and it polished the edges up really nice and smooth.

I called around first to a few places that have plasma and none would take the job, their excuse was that they couldn't guarantee me that the hole they were going to cut out would be centered. Why knows.

 

[dmcman73]

BTW, here is my build thread, you can see my setup I used to cut the bottom out of a keg: https://www.homebrewtalk.com/showthread.php?t=528153

 

[BeardedBrews]

If you really need a large opening in a keg you can cut the entire top+handles off right below the shoulder.

there have been a few people who do that but leave one of the handles to get an easy way to grab the thing.

 

[markstache]

@dmcman73: Do you think you could have made a larger cut with the angle grinder? My concern is that the maximum radius cut with a grinder will be too small. 13" is close, but I'd like to get 14" (let the jokes fly).

@BeardedBrews: This option is certainly still on the table, but I heard that the rolled top provides structural stability to the keg (i.e., it will go out of round if you cut the entire top off.

 

[Kwitty]

Strategically used C4! Half the fun of brewing is getting creative!!!

 

[markstache]

Tactical nuclear strike!

 

[dmcman73]

@dmcman73: Do you think you could have made a larger cut with the angle grinder? My concern is that the maximum radius cut with a grinder will be too small. 13" is close, but I'd like to get 14" (let the jokes fly).

@BeardedBrews: This option is certainly still on the table, but I heard that the rolled top provides structural stability to the keg (i.e., it will go out of round if you cut the entire top off.

Possibly, but my goal was to make it just large enough so that the lid I made would sit on the lip and make a good seal. I didn't check to see how much larger I could make the hole before the cutting wheel would hit the top edge of the keg.

If you need to go that wide, you're best bet is to find a good plasma cutter. i wouldn't mess with using a dremel tool, it won't come out as clean looking and it will take forever.

 

[ITV]

I used an angle grinder tool and I was able to only use 1 disk and I built a jig for the angle grinder to keep it centered. I did a series of cuts, each time going deeper with each pass. I didn't jam the angle grinder into the SS which is probably why others have gone thorough a lot more disks then I have. Once I cut through, I used a sanding disk on the angle grinder and it polished the edges up really nice and smooth.

I had the same experience, except I used the guard as guide.

I was able to get a 12" diameter cut using the guard as a guide. Without the guard you should be able to get a 13" hole but I doubt that you can get a 14" hole with an angle grinder. I recommend a plasma cutter for anything larger then a 13" hole.

 

[rekoob]

I used a dremel on the first one I did. Yes, it took a pretty long time and you do go through a few disks but it worked well and you can get the hole out past the top lip. I used a string and sharpie to mark the line first and then just take your time. fill the keg half full of water to help dampen the sound.

Then rest of the ones I have cut were with a grinder and I made a jig to hold the grinder as others have done. I adjusted it so the grinder was just touching the top lip.

The grinder was much faster but the hole not as large.

you could always use a grinder to cut it out and then a sanding disk/grinding disk to enlarge the hole. if you use the string/sharpie deal with multiple marks you should be able to keep it a nice curve.

Good luck, keep us posted.

 

[Auger]

If you really need a large opening in a keg you can cut the entire top+handles off right below the shoulder.

there have been a few people who do that but leave one of the handles to get an easy way to grab the thing.

I did this for my boil kettle, but left both handles and cut the rest off just below the seam where the top hits the side. At least on that keg, the sides were also thinner than the top so it cut faster. It may be a little out of round...but who cares? It still sits fine on my burner, and it has no structural issue holding 12gal of wort.

 

[stlblues5010]

I used a sawz-all with metal blade. Worked really well. Ran the foot along the edge as a guide. Used a large drill bit to make starting hole. Then clean up the edge with a grinder or Dremel.

 

[Pi Kapp Beer Guy]

Just cut 2 with an angle grinder. They look great. I second the fact you can probably go no larger than 13" with an angle grinder.

However, why change everything around an immersion chiller when you will probably want to upgrade to a counterflow chiller or a plate chiller in the future?

By the sound of it if you have the patience and time use the Dremel.

Good luck!

 

[EDF713]

I used the Dremel Metal cutoff discs, went through one pack of discs, then used the sander to deburr then sandpaper, so it's pretty smooth. One recommendation, if you have the original pot for your lid, set it on the top of the keg to mark for the cut if the pot handles aren't in the way, much easier than measuring with a string.

 

[bdogg171]

Why not use the angle grinder to cut as large as possible and then use a flat (grinding) disc to open it up the rest of the way? I may try it on a future project.