How do I drill a hole in a Keg big enough for a 1" Coupler?

[rudy0498]

I lucked into making friends with a guy who welds, and he is willing to help me weld fittings into my Keggles so I can stop fighting with weldless fittings. I ordered all of my fittings and realized that my 1-3/8" step bit won't be able to open a hole big enough for the OD of the 1" Couplers I need for the water heater elements. After some searching, I can't find any step bits that are larger than what I already have.

Has anyone else has found an affordable bit or knockout punch that can do the job? I'm on a fairly limited budget.

Thanks!

-Chris

 

[Xalwine]

Check the classifieds page. Some people will rent tools to other homebrewers. You probably wont need the punch for more than this project, you could get someone to lend you one.

 

[IrregularPulse]

Harbour Freight Step Bits.

 

[hopsalot]

a big step drill bit, like this one:
http://www.amazon.com/dp/B004TMS8V8...e=asn&creative=395129&creativeASIN=B004TMS8V8

 

[rudy0498]

Harbour Freight Step Bits.

Does harbor freight sell them any larger than 1 and 3/8"? I didn't see any on their website, but I haven't gone in the store.

 

[rudy0498]

a big step drill bit, like this one:
http://www.amazon.com/dp/B004TMS8V8...e=asn&creative=395129&creativeASIN=B004TMS8V8

The link doesn't work. But I did a quick step bit search and didn't see anything bigger than 1-3/8"....I think I need at least 1-5/8". I you found one that size or larger, can you please re-post?

 

[rudy0498]

The link doesn't work. But I did a quick step bit search and didn't see anything bigger than 1-3/8"....I think I need at least 1-5/8". I you found one that size or larger, can you please re-post?

Nevermind...the full link posted in the reply and that worked, but it is only a 1-3/8" bit.

 

[IrregularPulse]

I'm not sure. Him being a welder, does he have tools to make the holes or turn your coupler down to 1 3/8 OD?

And what coupler did you buy that is that thick?

 

[hopsalot]

I'm not sure. Him being a welder, does he have tools to make the holes or turn your coupler down to 1 3/8 OD?

And what coupler did you buy that is that thick?

it does seem very large, I would like to see some pictures when this keggle is complete

 

[rudy0498]

I'm not sure. Him being a welder, does he have tools to make the holes or turn your coupler down to 1 3/8 OD?

And what coupler did you buy that is that thick?

Unfortunately, he is a welder by hobby and not by trade. Here are the couplers I bought:

http://www.ebay.com/itm/200503167589?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1497.l2649

 

[hopsalot]

1/2" would have been more practical

 

[GilaMinumBeer]

Hole saw with carbide tips. Lowes.

 

[soundsandsuds]

Go to your local hardware store and buy a metal-rated hole saw. Much cheaper than the big step-bits.

 

[wildwest450]

1/2" would have been more practical

How many heating elements will fit through a 1/2" hole?

_

 

[BargainFittings]

You can have them butt weld it to the outside.

The threads on an element are smaller than 1-3/8"

 

[rudy0498]

Go to your local hardware store and buy a metal-rated hole saw. Much cheaper than the big step-bits.

The problem with a hole saw bit is that I already 1-1/8 inch holes in my keg from the weldless fitting that I need to bore out. So there is nothing for the pilot bit to grab onto.

I'm starting to think a knockout punch is my only option. Most of the cheaper punches that I have seen are rated for 10 gauge milled steel. That isn't hard enough to cut through stainless is it? I would happily rent one from someone if they have it, but that's probably a long shot.

 

[rudy0498]

You can have them butt weld it to the outside.

The threads on an element are smaller than 1-3/8"

That seems like a simple solution. If I were a welder, I might have thought of that...thanks!!!!

 

[tasq]

Unless he can TIG weld SS, and back gas properly, stay far away. I learned this lesson the hard way and you are on the path to have rusting keggles.

Not just any welder can do this task.

Don't say I didn't warn ya!

 

[rudy0498]

Unless he can TIG weld SS, and back gas properly, stay far away. I learned this lesson the hard way and you are on the path to have rusting keggles.

Not just any welder can do this task.

Don't say I didn't warn ya!

Thanks for the warning, but I trust this guy. He's the type of guy who isn't going to do anything unless he can do it well. He understood that I needed a TIG weld and that the kegs are ss. I even showed him yuri_rage's YouTube videos of his keggle welding so he understands what I want. Since he's working for free, I figure it's a risk worth taking.

Plus he sits 10 ft away from me at work. So he knows that if he screws it up, he will never head the end of it unless he quits his job.

 

[shafferpilot]

take the keg and the fitting to the guy and let him decide what size hole he wants.... and even let him cut it. I was once a welder apprentice to a master and it works just like painting a car. 90% of the important work happens before the welder even gets turned on. The fit of the two parts is the most important part to getting a good clean weld.

 

[tasq]

Thanks for the warning, but I trust this guy. He's the type of guy who isn't going to do anything unless he can do it well. He understood that I needed a TIG weld and that the kegs are ss. I even showed him yuri_rage's YouTube videos of his keggle welding so he understands what I want. Since he's working for free, I figure it's a risk worth taking.

Plus he sits 10 ft away from me at work. So he knows that if he screws it up, he will never head the end of it unless he quits his job.

Ok cool. I just wanted to make sure as I got burned this way.

I'll also agree with the above poster. My TIG welder DEMANDED that he be the one to drill the holes.

 

[Clementine]

I'm assuming you are trying to weld that into a hole rather than on to the out side of the keg. I was going to do this a electric setup but I was planning on drill a hole to clearance the element and a the weld a 1"NPT nut on the outside of the keg. This way you can make a gasket that seals against the face of the keg. The curvature of the keg does present a small problem but some planishing and grinding should flatten that out, he has to grind it to remove oxides before he welds anyway.

Clem