Cutting top off a Sanke keg using angle grinder

[shoebag22]

I didn't have any of the above mentioned tools and still don't. I do however have a dremel tool and a ton of cut-off wheels. Took forever, but I didn't have anything better to do. My goal was attained, I have a keg with the top cut off!

Are the dremel cut off wheels the sandpapery discs that come packaged in a tube?

 

[greenbirds]

The thin, flexible ones are for sanding. The slightly thicker rigid ones are cut-off wheels. If you flex them at all (or step on them, or apply any sideways pressure while cutting) they will break.

 

[justbrewit]

The ones in the little tube that are hard and fragile are the ones I used. Any side pressure, a loud noise, a fart, anything will make em break. I think I used about 20 or 30 of those things to take the top off the keg. It sucked, but it worked and I had 3 of 4 tubes of them so no biggie. WEAR EAR PLUGS! Lol it was hella loud

 

[MgMt_Home_Brew]

I just wanted to thank you guys for the inspiration and know how that I used to buy the tools I needed and get it done right. The first keg I cut had a smaller hole then I wanted so I modified the guard on the grinder and the second keg it where I wanted it.



Once I cut them open I used the step drill bits that I bought and drilled out holes for the spigot and sight glass. I had a friend print off some decals to mark my gallon and half gallon marks and this is the final result... thanks again guys!

 

[Bobby_M]

Very cool but did you double check the gallon marks? It looks like your 14 is where my 15 would be.

 

[MgMt_Home_Brew]

Yeah ... with the diptube that i made I had .62 gallons of dead space. So I filled the deadspace with water and then began my half gallon increments. I struggled with this idea and I am still not sure if I did it the best way that I could. But at this point it's done and I think I am going to just replicate the dip tube so the dead space is the same in all 3 of my vessels.

That is unless people convince me otherwise.

 

[SilverKing]

Thanks for everyone's input and Bobby's design I cut 2 of these today. Except for one spot where my grinder slipped loose and dropped(goodbye disc), they're perfect circles. The trick for me was to just cut barley into the surface and work back and forth in circles to get down through the steel. Instead of cutting straight through and then working sideways.

Had to use a couple wedge shims to level things out once it was assembled. The top ring on these kegs are a little banged up and not always level. Maybe a touch over-designed, but it's built to last for any others I'll have to cut in the future.

Also I used the disassembled keg spear for a centering post. I had to grind the tabs off it. Worked great.

 

[passedpawn]

Looks great!

For those intimidated by the jig: https://www.homebrewtalk.com/f51/simplest-keggle-cutting-jig-143048/#post1627203

 

[New-B-Brewer]

does anyone have a jig that uses the rim instead of center as the guide? I will soon be acquiring the last 2 kegs I need to make a 3 tier system and then will have to cut off the lids and drill all 3 kegs, I'm thinking the rim is a lot more stable throughout the cutting process than the center is. I don't yet a grinder yet so I havent been able to start playing with a jig yet.

 

[BreWirfel]

does anyone have a jig that uses the rim instead of center as the guide? I will soon be acquiring the last 2 kegs I need to make a 3 tier system and then will have to cut off the lids and drill all 3 kegs, I'm thinking the rim is a lot more stable throughout the cutting process than the center is. I don't yet a grinder yet so I havent been able to start playing with a jig yet.

it is more stable than you think. I made my jig long enough that the "arm" lay on the rim of the keg letting me adjust the pressure . I have done 3 kegs now, 1 with a rim that was totally banged up, and still made a perfect cut.

 

[Rick500]

does anyone have a jig that uses the rim instead of center as the guide? I will soon be acquiring the last 2 kegs I need to make a 3 tier system and then will have to cut off the lids and drill all 3 kegs, I'm thinking the rim is a lot more stable throughout the cutting process than the center is. I don't yet a grinder yet so I havent been able to start playing with a jig yet.

You don't need a jig if you're using the rim as a guide, although if you're cutting multiple kegs, it might be worth the effort to build one.

Here's how I cut mine:
https://www.homebrewtalk.com/f51/jig-free-keggle-cut-125911/

 

[mplutodh1]

Has anyone had any problems with the cheap angle grinders from Harbor Freight. I don't have a regular need for an angle grinder but will be needing one to cut the top off our Sankes and polishing them up with GatorGrit pads.

This one is under $20 right now at HF - anyone had luck with it? or does it burn out with prolonged use?
http://www.harborfreightusa.com/usa/itemdisplay/displayItem.do?itemid=43471

 

[llenrocs]

I bought a cheap pneumatic high speed cutter from Harbor Freight to cut my keg. Haven't done the deed yet, but the guard should follow the rim pretty well. It was 1/2 off, so only $8 when I bought it. If I get around to cutting it this weekend I will let you know how it worked.

http://www.harborfreight.com/cpi/ctaf/Displayitem.taf?itemnumber=47077

 

[Rick500]

Has anyone had any problems with the cheap angle grinders from Harbor Freight. I don't have a regular need for an angle grinder but will be needing one to cut the top off our Sankes and polishing them up with GatorGrit pads.

This one is under $20 right now at HF - anyone had luck with it? or does it burn out with prolonged use?
http://www.harborfreightusa.com/usa/itemdisplay/displayItem.do?itemid=43471

That's what I used. I actually got it for $9.99 a while back. I've used it several times and it's shown no sign of quitting so far. If it dies next time I use it, it's more than paid back its $10.

 

[mplutodh1]

I bought a cheap pneumatic high speed cutter from Harbor Freight to cut my keg. Haven't done the deed yet, but the guard should follow the rim pretty well. It was 1/2 off, so only $8 when I bought it. If I get around to cutting it this weekend I will let you know how it worked.

http://www.harborfreight.com/cpi/ctaf/Displayitem.taf?itemnumber=47077

Yeah I debated that - but figured the electric might be easier and I'd find other uses for it down the road. That one is like $7.99 after coupon right now though... so.

That's what I used. I actually got it for $9.99 a while back. I've used it several times and it's shown no sign of quitting so far. If it dies next time I use it, it's more than paid back its $10.

So apparently the "Heavy Duty" model is the one that I have a coupon for $17.99 - so I'll probably go that route.

 

[misterVT]

I didn't use a jig when I cut mine. Just set-up a few fingers on the rim and took my time. After seeing the results, I'm glad I didn't spend the time. Although if you are a perfectionist, by all means go with the jig.

 

[passedpawn]

I didn't use a jig when I cut mine. Just set-up a few fingers on the rim and took my time. After seeing the results, I'm glad I didn't spend the time. Although if you are a perfectionist, by all means go with the jig.

This jig took me about 45 seconds to make. Really. Might not work with all grinders because it requires the grip to come on a particular side.

https://www.homebrewtalk.com/f51/simplest-keggle-cutting-jig-143048/#post1627203

 

[mariojr]

I bought a cheap pneumatic high speed cutter from Harbor Freight to cut my keg. Haven't done the deed yet, but the guard should follow the rim pretty well. It was 1/2 off, so only $8 when I bought it. If I get around to cutting it this weekend I will let you know how it worked.

http://www.harborfreight.com/cpi/ctaf/Displayitem.taf?itemnumber=47077

I'm sure you already know this but, you need more than one of those cheap pancake style compressors to make that cutter work worth a damn.

Just my two cents.

 

[llenrocs]

I'm sure you already know this but, you need more than one of those cheap pancake style compressors to make that cutter work worth a damn.

Just my two cents.

I have a decent sized compressor with a 30 gallon tank, so no problem there. Thanks.

 

[nbspindel]

hey, i was wondering if anyone converting their kegs would be willing to mail me a few parts that come off the conversion? i use unaltered sankeys for fermentation, but have recently misplaced one of the retainer rings. I would much appreciate someone just putting a retainer ring into an envelope and mailing it to me. ideally 2 or 3 rings, just to have a few for backups cause i'm sure i'll lose more in the future. If you have the purple-ish o-rings (sometimes black) that are on the spear itself after removed, i would love a few of those for replacements too. Those can't even be found online, and the retainers are only $1 each, but shipping and handling from an online site brings the cost way up. This is more a favor. I can reimburse via paypal for a few stamps/shipping. Thanks.

 

[wilserbrewer]

hey, i was wondering if anyone converting their kegs would be willing to mail me a few parts .

Contact "Swagman", I bet if you bought him a beer and sent a few stamps as well, he just might send you a lifetime supply. Helluva guy that Swag.

 

[PokeFan]

hey, i was wondering if anyone converting their kegs would be willing to mail me a few parts that come off the conversion?

My plan is to convert my newly acquired keg next Saturday. I'm more than willing to send you the retainer ring when I pull it apart.

Shoot me a PM.

 

[Flomaster]

Thanks for everyone's input and Bobby's design I cut 2 of these today. Except for one spot where my grinder slipped loose and dropped(goodbye disc), they're perfect circles. The trick for me was to just cut barley into the surface and work back and forth in circles to get down through the steel. Instead of cutting straight through and then working sideways.

Had to use a couple wedge shims to level things out once it was assembled. The top ring on these kegs are a little banged up and not always level. Maybe a touch over-designed, but it's built to last for any others I'll have to cut in the future.

Also I used the disassembled keg spear for a centering post. I had to grind the tabs off it. Worked great.

Awesome jig. I have every thing I need at home to build this including the exact same angle grinder.

2x4's.. check
ratchet strap.. check
angle grinder.. check
thing to put in hole 1-1/4" pvc coupling... check
long bolt and nut to hold coupling to jig...check.


I like the idea of reusing the kegs pickup tube insert, but for me its very tight and was hard to get out I think I'll use the 1-1/4" pvc coupling like was mentioned in this thread.
https://www.homebrewtalk.com/f51/simplest-keggle-cutting-jig-143048/#post1627203

-=Jason=-

 

[tigmaster]

yeah thats a wild way to do er i just run a thin disc round and round then im thru

 

[tigmaster]

wow wild looking jig....crazy ideas

 

[Flomaster]

yeah thats a wild way to do er i just run a thin disc round and round then im thru

I want a perfect circle and there is no way I can freehand a perfect circle so that jig it is going to be.

-=Jason=-

 

[Flomaster]

well here is my version of the keg cutting jig.

first hole was a learning lesson: tried going opposite direction of the blade and dug in pretty deep to start off. went round a few times and found out it was easier to cut in the direction your cut off wheel is spinning. so at the end of my hole i had one side drooping slightly and my cut off wheel wanted to stray off the circle. this cut in slightly causing my circle to have what I would call what your weed wacker string or fishing line hooks into at the top end of the spool that little cut you make to keep the like from going away. not horrible but not perfect.

my second keg I fired it up eased it into the hole and let the weight of the jig make the cuts. went round and round moving the keg, and i'd walk around it until my cord would run out. Then I'd turn the keg again and repeat. this made for a pretty nice cut no burning into the metal just let the blade do the work.

well enough of my blabbering on to the photos.

-=jason=-

 

[Flomaster]

*bump* any objection to using a flapper sanding disk on my grinder to de-bur the edges of my hole. I figure its just sand paper but wanted to check first.

-=Jason=-

 

[lincoln]

that should work, I use something a little diff, regular sanding disks with a rubber backing pad....

 

[Flomaster]

I have those flapper disks already at home and I figure a quick run around the bottom edge and top edge would clean it right up. I'll go ahead and do it when I get home.

-=Jason=-