Kettle problem

Jessee · Aug 16, 2017

Hello,

I've been adding some upgrades to my kettle so I punched out two holes for attachments. However the second hole created a problem for me. When using hole punch it created a lip on right of the hole. I attempted to fix it after frustration and tightening up a fitting to "smash" the lip and I f I grind the lip down the hole is too big for the rubber seal. After doing that i created a unintended dent into it instead. Attached are photos. Hope you have a solution to fix it. With the dent it doesn't rest flush on the interior, picture to hopefully explain it.

Thanks Jessee

Frozenpuck · Aug 16, 2017

You should be able to grind that down either with a dremel tool or simple sanding. Find yourself a plug, likely 1/2 inch and proper O-Rings/washers. Treat the hole like any other attachment you would normally affix and you will be fine. Will look a bit silly but who cares, have a homebrew

BrunDog · Aug 16, 2017

That hole is work hardened, so it will be tough to modify without grinding. If you can't smooth the dent, you might go for a larger threaded bulkhead. That will require the hole to be bigger but you should probably grind it there.

golfindia · Aug 16, 2017

If the hole is close enough in size, dremel off that "ear", pull an NPT full coupling through it and silver solder it.

Add thermowell, presto.

Jessee · Aug 16, 2017

Hm okay good ideas. Maybe not perfect situation but a lot of new things to think about. Thanks for all your input. I'll be sure to let you guys know how I proceed

BrunDog · Aug 17, 2017

golfindia said:
If the hole is close enough in size, dremel off that "ear", pull an NPT full coupling through it and silver solder it.

Add thermowell, presto.

Great idea!!

Jessee · Aug 18, 2017

Well I ended up grinding off the lip with a dremel the best I could. I retried the fitting and it still was leaking. I got 1/2" silicone ring for the outside as well as the inside, that did the trick. Thanks for all the input and advice.