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Clean up the cut line, so that you don't open your arm up when cleaning it, and then test it before grinding away any more. IF you do need to grind away more, do it in very small amounts, test fitting as you go... It would really suck donkey junk if you were to grind away too much, too fast, and that lid won't sit right, or falls in if you look at it funny.
 
My buddy built two of these and he has the tools! He told me I can come over this weekend and we can clean it up. I think it would be smart to just clean it up all nice and use a towel to cover when chilling and not worry about the lid.
 
A towel soaked in StarSan does wonders... :D I use those (they're not dripping wet) whenever I have exposed wort/brew (post boil)...

If possible, find out what they usually put around the edge of the hole on keggles. I know the LHBS I visit converts them, and they have something going around the hole so that you won't get cut, ever... It has to be heat tolerant at least into the mid-200F range...
 
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I agree, what a butcher this guy should not be alowed near a plasma cutter again

I've seen worse. You ever get a peek at the keg that BierMuncher converted himself? :D

HopBag6.jpg
 
I always use a lid when waiting to get up to boil. Maybe its not that big of a difference, but it seems to get to temp faster.
 
Did you opt for the flap disc or what? Just curious. I could enlarge the hole on one of my kettles to make a lid fit better.
 
I used a angle grinder to make it round and fix some of the spots and used a grinder bit on my drill to touch it up then a sander to make it smooth.
 
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