Welding 101 = Fun Brutus Build

[SouthernYankee]

Looks fantastic. This is exactly what I want to do. I may have to copy some of your ideas if you don't mind. I will give you full credit. I might even pick up the same welder as you. What did you use to buff the steal before priming and painting? Also what did you use to clean up the welds? Dremel? What bit?

Thanks.

Gregg

Thanks and feel free to use anything you want. The welds were grounded down with a 4 1/2" angle grinder with a grinding disc (buy at least two). Lowes and HD both sell them. Dont even try to use a dremel, you will be sitting there for days!

To clean up the steel. I used a 50 or 60 grit flap disc which I changed out with the grinding disc on the angle grinder. Once again buy a few.

 

[SouthernYankee]

Also would you be willing to share the dimensions you used for this? Or maybe the blueprint/cad drawing?

Thanks.

Gregg

The blueprint was drawn out. So the best I can do for you is post a photo of it. Overall height is 27". Also remember that I added the 45 degree tubing to the top corners after I made the drawing.

 

[diatonic]

Wow, the dimensions on our stands are nearly identical

 

[ghart999]

Thanks for posting your blueprints and the advice.

 

[ghart999]

What software do you guys use for your blueprints? Anything free that works decent?

 

[diatonic]

What software do you guys use for your blueprints? Anything free that works decent?

Google SketchUp is great, and free. Lots of tutorials, and great for conceptualizing.

I'm using AutoCAD lately, which is far from free, but it is awesome . Employer bought it for a recent project and I'm digging it.

 

[SouthernYankee]

Wow, the dimensions on our stands are nearly identical

WOW.. almost to a tee. I like the dimension's a lot. It isn't to big and not to small. Also, If I wanted to use anything other then keggles on the stand. Lets say a deep fry kettle or household pot to boil. Everything will fit on top and have plenty of room to work with.
I know for some the footprint might be too big. But once you have your kegs setup on top of it and stand there for a moment. Its just right.
But everyone has there option on size. For me the size is just right for my needs.

 

[DrawTap88]

I'm thinking of doing a rig, eventually, and this thread is going to be very helpful. Thank you all for sharing your experience.

 

[SouthernYankee]

I'm thinking of doing a rig, eventually, and this thread is going to be very helpful. Thank you all for sharing your experience.

Not a problem. I really wanted everyone whom never welded before know that it isn't that hard at all with a flux core welder. My welds might never pass an x-ray. But for me it is a great satisfaction building it myself.

I thought I would also share the build process. I know there are a alot of builds on here.. but just to show everyone what a never before welder can do.

 

[SouthernYankee]

Update: 3/11/2010
Finished painting the rest of the stand lastnight. This morning everything was dry. I had time to put the diamond plate on and install the burners. Water filter added to the side.

Still need to install the black pipe etc....
Its getting there!

 

[jlandin]

Did you already drill out the banjo orifices for low pressure propane? If so, I'm interested in the hole you went with.

I have this chart, but I'm not sure what the optimal BTUs per hour should be for these banjos.

--
Josh

 

[diatonic]

Wow, looking very nice. A few questions:

1) How are you mounting your pumps?
2) What are your plans for a control panel?
3) Could you ship two of those wind screens to my address since our builds look like siblings?

 

[ghart999]

Looks fantastic and exactly what I will be doing.

A few questions.

1)What did you use to cut your steel? I was thinking of a 6" chop saw I saw on Northern tools for $50 as I imagine my angle grinder won't suffice for perfect cuts, especially 45 degree cuts.

2) Where did you get the material for the wind screens?

3) What material is the diamond bottom and were you able to weld it to the frame or use screws or something?

You are my hero and I am so copying your design.

 

[SouthernYankee]

Did you already drill out the banjo orifices for low pressure propane? If so, I'm interested in the hole you went with.

I have this chart, but I'm not sure what the optimal BTUs per hour should be for these banjos.

--
Josh

No, these are high pressure burners. 20-30 psi. I'm just going to use propane right now with gas valves going to the burners which will adjust the flame.

 

[SouthernYankee]

Wow, looking very nice. A few questions:

1) How are you mounting your pumps?
2) What are your plans for a control panel?
3) Could you ship two of those wind screens to my address since our builds look like siblings?

1, The one pump I have will be mounted in the middle. I will have to drill several holes and mount the pump with a u-bold (not sure if this is the correct name for it. But have seen them in HD) to the underside of the diamond plate around the middle tubing attaching it to the pump.

2, No control panel. Right now. I'm just doing straight propane with the gas valves to each burner. I will plum the middle burner with a gas valve but Will plug that one end of the valve up for future use.
I going to wait awhile and see how this stand works out before I even think about building a control arm on it and start setting it up for all the electronics. Which is going to have to wait awhile due to budgets.

3, Would like to, but Im out of plate steel. Bought enough for the three shields.

 

[SouthernYankee]

Looks fantastic and exactly what I will be doing.

A few questions.

1)What did you use to cut your steel? I was thinking of a 6" chop saw I saw on Northern tools for $50 as I imagine my angle grinder won't suffice for perfect cuts, especially 45 degree cuts.

2) Where did you get the material for the wind screens?

3) What material is the diamond bottom and were you able to weld it to the frame or use screws or something?

You are my hero and I am so copying your design.

1, I used a 10" table saw. All I did was change out the wood cutting blade with a 10" metal cutting blade. I wanted to save some cash from having to buy a chop saw. I already had the table saw on hand.
That chop saw in my option will work. It can cut the size tube 1.5 which I used on my build.
I have said it and will say it again. I wouldn't recommend using a angle grinder. Sure, you COULD use it. But once it came time to cut NICE 45 degree angles..I don't think so!

2, The 16ga carbon sheet metal was bought local. But Ive have seen them being sold on eBay. Just type in sheet metal.

3, The diamond plate is think aluminum which I had cut to size. All I had to do was cut out notches out for the corners and center tubing . I countersunk the screws into it. Using #8 1 inch sheet metal screws.

Hero...WOW. Thats is a strong word my friend. But thanks for the compliment!

 

[jlandin]

No, these are high pressure burners. 20-30 psi. I'm just going to use propane right now with gas valves going to the burners which will adjust the flame.

Ok, so you are going with high pressure regulators. I'm converting my banjos to low pressure propane, that's why I asked. Thanks,

--
Josh

 

[ghart999]

1, I used a 10" table saw. All I did was change out the wood cutting blade with a 10" metal cutting blade. I wanted to save some cash from having to buy a chop saw. I already had the table saw on hand.
That chop saw in my option will work. It can cut the size tube 1.5 which I used on my build.
I have said it and will say it again. I wouldn't recommend using a angle grinder. Sure, you COULD use it. But once it came time to cut NICE 45 degree angles..I don't think so!

2, The 16ga carbon sheet metal was bought local. But Ive have seen them being sold on eBay. Just type in sheet metal.

3, The diamond plate is think aluminum which I had cut to size. All I had to do was cut out notches out for the corners and center tubing . I countersunk the screws into it. Using #8 1 inch sheet metal screws.

Hero...WOW. Thats is a strong word my friend. But thanks for the compliment!

So was the sheet metal already in a circle or did you curve it around and weld it into a cylinder? Also what was the diameter of the circles?

 

[SouthernYankee]

Ok, so you are going with high pressure regulators. I'm converting my banjos to low pressure propane, that's why I asked. Thanks,

--
Josh

Right, I'm using a HP regulator for now. Let me guess. You want low pressure on yours so the flame wont blow out on the igniter once turned on?

 

[SouthernYankee]

So was the sheet metal already in a circle or did you curve it around and weld it into a cylinder? Also what was the diameter of the circles?

The sheet metal was straight. Then curved into a ring and the ends welded together. The size of them: 12.5" inside diameter by 4" wide.

 

[ghart999]

OK. So you started with roughly a 40" long piece of 16G sheet metal and curved it into a circle. Was this difficult to curve and hold in place while you welded it? How did you do this exactly?

Maybe I should just buy a table saw too instead of a chop saw. Table saw can be used for everything whereas chop saw is so limited, albeit smaller than a 10" table saw.

 

[jlandin]

Right, I'm using a HP regulator for now. Let me guess. You want low pressure on yours so the flame wont blow out on the igniter once turned on?

I'm going low pressure because the honeywell solenoid furnace valves I'm using on the HLT and MT work with low pressure propane.

--
Josh

 

[SouthernYankee]

OK. So you started with roughly a 40" long piece of 16G sheet metal and curved it into a circle. Was this difficult to curve and hold in place while you welded it? How did you do this exactly?

Maybe I should just buy a table saw too instead of a chop saw. Table saw can be used for everything whereas chop saw is so limited, albeit smaller than a 10" table saw.

Yes, roughly a 40" long piece of sheet metal and using the outside of a home depot 5 gal. plastic cooler to roughly make the ring. Start at one end and start to form it over the outer part of the cooler and shape it around it. If you don't have a cooler then try to find something round. Maybe a Corney.

Once, I had the size I wanted. I took a pair of vise grips to hold the ends together. I placed a "tack" weld in the middle..then started to weld from one end to the other end of the ring.

Believe me, if I had a chop saw I would of rather used it. Working with a 60" piece of tubing can be a pain to saw. I had to lay the piece on the saw table then clamp it in several different places on the "saw guide" so it wouldn't move while I was cutting it.
The chop saw you wouldn't have this problem.

 

[SouthernYankee]

I'm going low pressure because the honeywell solenoid furnace valves I'm using on the HLT and MT work with low pressure propane.

--
Josh

Thanks for the link Josh. I might have to look at these later on down the road.

 

[Fletch]

Thanks for the link Josh. I might have to look at these later on down the road.

Yankee and Josh, you guys should do like I do and go visit a scrap yard. You can frequenly find a scrapped furnace, and pull these parts out:

Automatic gas valve and

Ignition/valve control module. Be sure to pull the pilot/ignitor out, too, and the wires connecting them.

Over the years I've picked up several of these for brew systems (my home system, Club rig, a couple of friends rigs), and the most I ever paid for them was $5! A couple of times, when I was buying some stainless or copper item, I got the furnace parts for free. The one on my home rig was just such a freebie, and it's been running for over 8 years, no problem. And if the parts you find in your local yard are for Natural Gas, you can pick up a conversion kit for a few bucks on eBay.

With these installe, all you have connect your temp control to send 24 vac to the module on a call for heat. The module opens the Pilot Valve and generates a spark at the pilot, sensed the pilot flame, and opens the Main Gas valve to your burner. If the pilot blows out (or is drowned by a keggle overflow), the module cuts the Main Gas and repeats the ignition sequence, which takes less than 5 seconds. MUCH more reliable than using a Standing Pilot valve. I fill my HLT the day before a brew day and have the rig on a simple light timer. By the time I'm ready to start, I already have plenty of hot water.

 

[SouthernYankee]

Yankee and Josh, you guys should do like I do and go visit a scrap yard.

Thanks for the info Fletch

 

[shawnguinn]

I love your system, it looke great!!!!!

 

[SouthernYankee]

I love your system, it looke great!!!!!

Thanks Shawnguinn!
Cheers!

 

[SouthernYankee]

Update: 3/13/2010
Nothing really new to report or post.
In the process of putting together the black pipe propane supply.

Still waiting for the stainless gas lines and a few fittings to arrive via mail. Hopefully they will arrive on Monday.

 

[diatonic]

I'm jealous that you'll be ready to brew on yours before I'm ready to brew on mine .

Did you use pipe dope on the gas line threads or the yellow teflon tape? Also, I have the same red-handled brass valves on my gas beam, so we continue the similarities!