Oops I cut holes too big on keggle!

[NewtoBrewing]

I plasma cut 2 holes on each of my kegs for ball valves and thermometers with my friend's plasma cutter. There is a problem though, three of the holes I cut are too big for my 1/2" SS couplings. I know keg walls are thin and hard too weld, am I screwed on these kegs? If you held the coupling directly in the center of the hole there is an eighth inch gap all the way around it. Will this still be weldable or filled in or is the stainless too thin on a keg? The coupling can move around in the hole......I know nothing about welding stainless, so will someone with experience be able to fix this you think?
Cheers,
Brent

 

[BrewBeemer]

I would first machine the coupling OD a cleanup cut then machine a sleeve that will fit the keg nice and tight, Tig it all together. All is not lost it can be saved.

 

[brewmonk]

hole's not too big, you just need a bigger ball valve and coupler.

 

[Raider-11]

Short of welding a patch or going with a 3/4" coupler and using reducers, theres not much else you can do, by the way what were you going to do with the coupler once you cut the holes, do you have weldless couplers, you should invest in a step bit, it makes a much nicer hole.

 

[brewmonk]

one other thought

weld in a close hex nipple instead, to fill the gap.

 

[samc]

one other thought

weld in a close hex nipple instead, to fill the gap.

This

 

[DaleP]

An 1/8 inch gap is not hard to fill and clean up. Take it too a good tig welder.

 

[IrregularPulse]

I cut my holes too big on an aluminum pot. Had stainless fittings. WElding wasn't an option. I picked up a tube of JB Water Weld for $8. It's safe up to 300 and is safe for potable water. So that's an option. Worked great for me.

 

[Apoxbrew]

i really know absolutely nothing about welding so this might be a way stupid idea... but if you know how to weld anyway, couldn't you just get some SS fender washers, weld those into place on either side, and then run your gear through the new, perfectly sized, hole?

 

[Henrythe9th]

2nd the going with 3/4 coupler and ball valve,, you'll like the larger flow from 3/4"

 

[NewtoBrewing]

I took the kegs to a custom metal shop today with my couplings and the owner laughed when he saw the cutting I did. He told me next time to let him cut the holes and weld everything start to finish, just mark the spots. He laughed mainly because it is an easy fix for him and he saw me stressing over my ****ty plasma work. We'll see if he can fix them up, he seemed really confident about it. Hope this works (Crossed fingers)

 

[ScubaSteve]

Sounds like you have a decent resource there...a lot of places like that don't like dealing with hobbyists...they can be rude if you're not "in the biz". Good luck!

 

[Raider-11]

I took the kegs to a custom metal shop today with my couplings and the owner laughed when he saw the cutting I did. He told me next time to let him cut the holes and weld everything start to finish, just mark the spots. He laughed mainly because it is an easy fix for him and he saw me stressing over my ****ty plasma work. We'll see if he can fix them up, he seemed really confident about it. Hope this works (Crossed fingers)

What did he say he would charge by the hour, the place I'm takeing my keggles BC Fabricators charges 60 bucks an hour and Neal the shop manager said it would maybe take half that to do all three keggles but as ScubaSteve said Im in the biz and have used ther services for years at my job.

 

[NewtoBrewing]

He said he'd do the 6 welds for $50 bucks this time, but he'll do it cheaper next time if I let him cut the holes first. He said it's actually less work for him if I let him cut the holes. I haven't seen the finished product yet so we'll see tomorrow or tuesday. I'll post pics.

 

[Raider-11]

He said he'd do the 6 welds for $50 bucks this time, but he'll do it cheaper next time if I let him cut the holes first. He said it's actually less work for him if I let him cut the holes. I haven't seen the finished product yet so we'll see tomorrow or tuesday. I'll post pics.

That sounds like a good deal, I'm sure he'll do a good job, post some pic's if you can please.

 

[NewtoBrewing]

Here are the pics. Came out great and only $50 dollars. If you're in the Central Valley hit me up for his info....

 

[NewtoBrewing]

That was one of three I had done, the half couplings for the thermometers and couplings for the ball valves. Can't wait to plumb everything and brew!

 

[Raider-11]

Looks real nice I'm glad you found someone that knows what he's doing and can fix the oops's we sometimes make.