Simplest (?) Keggle Cutting Jig

[Scut_Monkey]

unless you are doing a lot of kegs, I dont see why you would need a jig?

A string with a loop tied in it to fit over the couplers center well.

A tape measure to make a mark on the string for diameter, and a black magic marker to mark the sting and draw the circle on the keg.

The kegs rim and the back of your hand makes for a perfect guide for going around the mark lightly scoring it the first time around with the grinder.

After that the score mark and the rim keeps the grinding wheel in place.

Many people don't use a jig and get good results. I'm doing 3 kegs eventually so I figured I might as well build a jig. I'm not accustomed to using an angle grinder so I figured it would help with my lack of skills as well. In the end I wanted my keggle to look perfect so I decided a jig was the best way to guarantee this. But if you can do it without the jig go for it.

 

[Bobby_M]

The jig makes it nearly impossible to screw up. The hole is a perfect circle and there are no oops gouges. Craftsmen work freehand and engineers use jigs and guides. Art vs. perfection I suppose. I can't draw a straight line.

 

[passedpawn]

The jig makes it nearly impossible to screw up. The hole is a perfect circle and there are no oops gouges. Craftsmen work freehand and engineers use jigs and guides. Art vs. perfection I suppose. I can't draw a straight line.

nice bobby. +me.

 

[shortyjacobs]

The jig makes it nearly impossible to screw up. The hole is a perfect circle and there are no oops gouges. Craftsmen work freehand and engineers use jigs and guides. Art vs. perfection I suppose. I can't draw a straight line.

<-------Lazy engineers don't use jigs or guides

 

[Scut_Monkey]

I wasn't even able to draw a good circle with the string and marker method. I figured doing a similar thing with the angle grinder free hand would be less than ideal for my liking.

 

[mordantly]

i used string on a plasma cutter and it wasnt exactly circular..

 

[Scut_Monkey]

i used string on a plasma cutter and it wasnt exactly circular..

Hmmmm..... Maybe I should take that plasma cutter off your hands sir.

 

[OLDBREW]

i used string on a plasma cutter and it wasnt exactly circular..

The kegs handled rim around the outer perimeter is solid and is what guides the tool. A string can stretch and a shakey hand doent help.

A large standard pot lid is 12" so I cut my holes that size.
A lid on a keggle is great for storing, maintaining heat, or getting liquid up to a boil faster.

 

[mordantly]

i'm not rich enough to own a cutter. i had to trade some beer for the use of it. and i still need to make good on it. i told my friend id give him a case. now a year later i better give him a keg.

i cut a 12" orifice as well. yeah the stretch/bind factor was there. and keeping current on dimensional tolerancing, i had +/- .1 and it is within +/- .05 and thats ****in acceptable on a pot.

 

[passedpawn]

unless you are doing a lot of kegs, I dont see why you would need a jig?

A string with a loop tied in it to fit over the couplers center well.

A tape measure to make a mark on the string for diameter, and a black magic marker to mark the sting and draw the circle on the keg.

The kegs rim and the back of your hand makes for a perfect guide for going around the mark lightly scoring it the first time around with the grinder.

After that the score mark and the rim keeps the grinding wheel in place.

You don't need a jig. I have done 4 kegs in the past 3 weeks. I'll probably do 2 more in the next couple of weeks. This jig makes it quick work. I f'ed my first one trying to do it freehand.

 

[Orfy]

I've added this to the project locator sticky.

 

[OMJ]

used this today and it was really easy thanks for the idea passed.

 

[Reelale]

What's the largest diameter this will cut? I know it is limited to the handle length, but from the center of my handle to the blade is only about 8".

Edit: Never mind, I just remembered this concept called math. R=1/2D

 

[passedpawn]

I cut 12" (diameter!) holes, which is about the limit due to the rim of the keg.

 

[Reelale]

Oh yeah, if you've got a cheap angle grinder from HF, it won't work. The handles are 180 degrees to the blade. There is no way to use the handle at 90 degrees to get the blade perpendicular to the keg top. Looks like using Bobby's jig for me.

 

[mordantly]

if i do another one, id fill it half full with water. i have some spots of rust where slag adhered. after the 5 gal cools off in there right now, i gotta clean the crap outta it.

 

[Reelale]

sparks from a grinder or slag from a plasma cutter?

 

[Reelale]

I just got a keg that was half-full of 2 month old Bud lite. I had to taste it. It was absoultely the worst s--t I have ever tasted. I will never dis' my own homebrew again!

 

[passedpawn]

I just got a keg that was half-full of 2 month old Bud lite. I had to taste it. It was absoultely the worst s--t I have ever tasted. I will never dis' my own homebrew again!

I was at a street fair tonight. There was a trailer with a bud tap. $3. I had to taste it. It was absoultely the worst s--t I have ever tasted. I will never dis' my own homebrew again! True.

I can't believe you tasted it. That is funny as hell.

 

[mordantly]

bud banquet when it is extremely fresh and nearly frozen on tap is the greatest any domestic swill can be. ie. the dragstrip in 110F weather, its all the calories without that irritating buzz. and a great colon flush to boot.

 

[Reelale]

Yeah the guy told me it was 2 months old, but when I broke the seal it was stilll carbonated, not flat. It smelled ok, but it was awful . I must say that budlight does not age well. But I've got the materials for a brand new keggle.
the beer is feeding the grass in the back yard. That keg had a lot of pressure!

 

[mordantly]

yeah, i pressed the ball the other night on my anheiser-busch keg a buddy gave me and what did i get? a face-full-o-beer. yucko.

 

[autoferret]

I'm going to have to give this a try. thanks for the idea on cutting the top off. was just going to free hand a plasma cutter...

 

[passedpawn]

I'm going to have to give this a try. thanks for the idea on cutting the top off. was just going to free hand a plasma cutter...

Great. Let us know how it goes.

 

[Hillbilly_Bill]

I have been procrastinating doing the cut on my keg... now I'm glad I waited... the idea of making the hole the size of a large lid never entered my mind... duh.
Thanks a million for posting your jig and for whoever mentioned the 12" pot lid.

 

[TheFlyingSparge]

Smart thinking. That's the way I'll do mine. Prost!

 

[HI_SALENITY]

Cool , great idea!

 

[PGO]

Just in time, buddy and I are going to convert a half dozen kegs this week.

PROST!

 

[brew2you]

I'm building this jig this weekend. Looks simple enough.

 

[Sizz]

It's cool how everyone comes up with different ideas for these jigs. I was planing on using a hole saw like someone else suggested but mine was a tad too big to fit inside. I ended up using the hole saw to cut a hole in a small 2x4 piece, drilled a thru hole to the grinder and secured it with a 1/4-20 bolt. The screw on the other end keeps it all level.