Keggle Cutting

[The Pol]

I bought an angle grinder today, and some step drills, starting work on a new keggle... any tips? This is going to suck ha ha ha

Pol

 

[Yuri_Rage]

It shouldn't suck at all. It should be quite a bit of fun, really. Biggest tip I can give you: don't get in a hurry - have a bit of patience when measuring and cutting.

See this series of videos:

 

[the_bird]

biggest thing is to NOT try and cut all the way through with one pass of the grinder. Let the wheel do the work, let it take three or four passes. Obviously, draw out your circle with some market; FYI, the bottom of an ale pail is a great size for the hole. Clean up the edge with a file and some sandpaper, and you're good to go. Take your time, but it won't take that long - it's easier than you think it will be.

 

[Denny's Evil Concoctions]

Don't press to hard when drilling and make sure you oil the bit. SS doesn't cut well with to much pressure.

 

[Yeast Infection]

Im sure you would do this.....but...wear eye protection!!

 

[Bokonon]

I'd recommend filling the keg with water to reduce the noise as well as wearing ear plugs.

 

[The Pol]

Sweet, it is marked... my new 4.5amp 4.5" angle grinder will get its first test... then to the step drilling. QUESTION, isnt the OD of a 1/2" MPT nipple about 5/8" or so? I am making my own weldless fitting for the ball valve and want to make sure I have the sizing correct. Thanks.

Pol

 

[seawort]

yep... what they said about the cutting and the drilling. It really goes fast once you start and is pretty fun. Now... don't get stuck at 3/4" drilling like I did and think you can just ream it out... I need to get another drill bit or something, I wrecked some of the threads on one of the nipples getting a bit too forcefull trying to make the undersized whole work

 

[the_bird]

Sweet, it is marked... my new 4.5amp 4.5" angle grinder will get its first test... then to the step drilling. QUESTION, isnt the OD of a 1/2" MPT nipple about 5/8" or so? I am making my own weldless fitting for the ball valve and want to make sure I have the sizing correct. Thanks.

Pol

I think so, but that's why they make tape measures, son...

I'd keep it with you when you drill, and check it each time you make a "step" and you know you're close.

 

[The Pol]

Okay, I have done a couple passes, and I am getting no where... alot of sparks and heat but very little cutting going on here... what gives? Is it really this hard with an angle grinder?

Pol

 

[the_bird]

keep going, it usually takes three or four passes. You ought to be seeing a groove be made. You can put a LITTLE pressure on the tool just don't over-do it.

 

[Denny's Evil Concoctions]

Are you using the thin cutting wheels or thick grinding ones? And they do take about 30 mins to make the hole.

 

[The Pol]

starting to get somewhere... thanks

 

[Denny's Evil Concoctions]

Just think of it as 30 mins of peace (al be it noisy even with earmuffs). No sane person will want to come near you with all that noise and sparks.

 

[The Pol]

Okay, well it took nearly an hour... I think that my cutting wheel was perhaps too thick... anyhow, had a moment of "finger meet 11,000 RPM silicon cutting wheel", but I am all bandaged up now, only went up to my fingernail tip!! It looks phenominal, have just a little deburring to do but that is about it, pics soon. I will drill for the ball valve assy. this weekend too. Does anyone know if Lowes carries silicone O rings? Or any high temp O ring? Thanks all!

Pol

 

[Yuri_Rage]

Don't press to hard when drilling and make sure you oil the bit. SS doesn't cut well with to much pressure.

Use a fair amount of pressure, low RPMs, and plenty of cutting oil. Too much pressure will heat the metal and dull your bit. Too fast a cutting speed will heat and work harden the metal, making your job REALLY difficult.

 

[Cede]

Wear good gloves and glasses as well as ear plugs. It's for your safety.
Getting hot stuff in the eyes really hurts, harming your ears is not cool, and drilling a hand makes drinking beer harder
Don't forget to lubricate while drilling.

Be gentle with your tool, not like me when I was cutting my car:

Yes, there's fire in it !
Hoops, made a mistake ?

 

[Bobby_M]

Yeah, too late now but hopefully this will benefit others. You want a really thin cutting wheel and make sure it's meant to cut metal. They have ones specifically for concrete too and you don't want that. I know they make cutoffs at about 1/8" thick but that forces you to grind away double the metal of a thinner wheel. It took me 15 minutes.

 

[dibby33]

...and hot sparks up the nose buring the nostril hairs really stinks.

 

[The Pol]

Drilling here in a few minutes.... tick tock...

 

[The Pol]

Here it is... ready to recieve the ball valve! The step drills that I bought worked awesome, got a set of 3 for $10 at Harbor Freight, they cut it like butter! Thanks yall!

http://i168.photobucket.com/albums/u189/PolTavern/KettleStepdrill.jpg
http://i168.photobucket.com/albums/u189/PolTavern/Keggle4.jpg
http://i168.photobucket.com/albums/u189/PolTavern/Keggle2.jpg
http://i168.photobucket.com/albums/u189/PolTavern/Keggle1.jpg

Pol

 

[the_bird]

Looks good! A file and some sandpaper, clean up that edge, and you'll be all set!

 

[The Pol]

Hey, yah, it turned out great, just a little deburring to do and it will be set for my next session! I am excited!!!!!

Pol

 

[Orfy]

 

[dixon72]

I just cut my kegs open the other day and what helped me out a lot in the deburring (sp?) department was using a sanding wheel. It's also a great way to fine tune that perfect circle without screwing it up, or fixing it if you did screw it up. :cross:

You can buy them in 60, 80, and 120 grit and can be found next to the grinder cutting wheels at Lowes. By hitting the top and bottom sides of your cut you can achieve a really smooth finish.

-Dixon

 

[seawort]

i'm really wishing I had taken the stems out of the kegs before i cut them now. I would like to use the cut out tops as lids but its no where near as easy to get the stems out without the keg for leverage.

 

[Denny's Evil Concoctions]

Use a vice?

 

[alemonkey]

Or you could do like I did, and have a friend who's an ex-machinist cut the top off with a plasma cutter and weld the fittings on with a TIG welder. For free

 

[Lil' Sparky]

Ummm, I don't think Miller will be willing to refund the deposit on that keg after that accident with your grinder and drill (should you ever try to return it).

 

[Lil' Sparky]

Oh, and nice work!

Glad you didn't grind a finger off in the process. Gotta wear gloves when using a grinder!