Repair 10 gallon cooler - Need collective input

[iamperplexed]

I picked up a bunch of used gear from a guy on craigslist recently and included was a 10 gallon cooler. I didn't notice until after I brought it home that the previous owner pretty much destroyed the hole where the spigot once was. It looks like it was rarely used but it was obviously being used as a mash tun because it includes an older, plastic false bottom .

I got such a good deal on all of the gear, it's not a major issue. That being said, I would love to salvage this cooler. Can anyone suggest a fix? It looks like the previous owner used some type of crude technique to widen the port in the cooler. A good portion of the gear is very old and antiquated so maybe he was using a bung and piece of tubing for a drain? Or an oversized spigot? The opening is now approximately 1 1/4" at the widest point.

Long story boring, here's a picture of the damaged goods. Any ideas for a repair?

 

[IrishBrewer74]

You may not need to repair at all. Build your own bulkhead or buy one like here http://www.northernbrewer.com/shop/cooler-bulkhead.html you'll need it whether this cooler is salvageable or if you buy a new one. The o-rings are good sized and squishy... They might be sufficient to make a good seal.

Good luck.

 

[Melana]

Have you tried a bottling bucket spigot and some plumbers tape?

 

[iamperplexed]

You may not need to repair at all. Build your own bulkhead or buy one like here http://www.northernbrewer.com/shop/cooler-bulkhead.html you'll need it whether this cooler is salvageable or if you buy a new one. The o-rings are good sized and squishy... They might be sufficient to make a good seal.

Good luck.

The hole is too large for the bulkhead and o-rings in particular. That was the plan originally. I looked into a larger fitting (even in brass) but the parts list pricing quickly became higher than a replacement cooler. Thanks for the suggestion anyway.

 

[iamperplexed]

Have you tried a bottling bucket spigot and some plumbers tape?

I haven't because I wasn't sure if a bottling spigot was considered hi-temp, even if it would make a seal. I'll look into it, thanks.

 

[IslandLizard]

Very repairable.

Fabricate an insert from a piece of PVC pipe or conduit that just fits the hole. The inside of that pipe should fit your bulkhead quite snugly, plus it gives you some support to clamp down to.

JB weld and silicone caulk are your best buddies.

Instead of an O-ring, try a flat silicone washer, backed by a SS washer (or "shim").

 

[wilserbrewer]

You could make a spigot and bulkhead from cpvc pipe and fittings available at HD Lowes etc...
https://www.homebrewtalk.com/f11/cpvc-ball-valve-172154/

Or the fast and dirty effective method of shoving a stopper from the inside and passing a tube through the hole in the stopper works great...ala Denny Conn
http://hbd.org/cascade/dennybrew/

http://homebrewforums.net/discussion/129/very-simple-mash-tun/p1

https://www.homebrewtalk.com/f11/ten-minute-cooler-mash-tun-conversion-125108/

 

[ChuckO]

Take a look at this thread. https://www.homebrewtalk.com/f11/my-new-mash-tun-268370/ I'm using something like this for a mash tun and have a second one set up with a 2000 watt element in the side for a combination HLT, complete BIAB and sous vide water oven. Things work great and made a happy solution to warped/cracked Rubbermaid insides.

 

[iamperplexed]

Take a look at this thread. https://www.homebrewtalk.com/f11/my-new-mash-tun-268370/ I'm using something like this for a mash tun and have a second one set up with a 2000 watt element in the side for a combination HLT, complete BIAB and sous vide water oven. Things work great and made a happy solution to warped/cracked Rubbermaid insides.

I love that build. It's the first thing I thought of when I ran into the issue. My turkey pot is a little narrow but my "plan b" is to cut a couple of notches out for my handles and use it as an insulating vessel for my pot when I'm doing small batch BIAB.

 

[iamperplexed]

You could make a spigot and bulkhead from cpvc pipe and fittings available at HD Lowes etc...
https://www.homebrewtalk.com/f11/cpvc-ball-valve-172154/

Or the fast and dirty effective method of shoving a stopper from the inside and passing a tube through the hole in the stopper works great...ala Denny Conn
http://hbd.org/cascade/dennybrew/

http://homebrewforums.net/discussion/129/very-simple-mash-tun/p1

https://www.homebrewtalk.com/f11/ten-minute-cooler-mash-tun-conversion-125108/

I tried the stopper / tubing idea assuming that's what the original owner widened the hole for but it leaked. I might be able to clean it up a bit a and get a better seal. All great ideas, thanks.

 

[iamperplexed]

No fix yet but in the meantime it's working great as insulation for my small batch BIAB brews in the kitchen. I usually do 3 gallon brews in my 7.5 gal turkey pot.

151.5° down from 152 after an hour on the first run but I credit the towels. I only used 1 towel on my second mash and lost 3 degrees.