The Mash Tun Project

1/3/10 - Good lawd this thing has stressed me out somethin awful! I have a sweet 3 tier system (on the left - circa 2003), but the damn thing has such a problem with heat loss that I have decided I just cannot use it. Even in hotter outside temps, it just doesn't do well. I had had enough of it, and I was ready to start all grain brewing for good, but I knew I needed to get this thing fixed or else I'd be screwed.

First Option - Wrap That Rascal
I had seen some people wrapping their mash tun kettle with water heater insulation. I went to Lowes and looked at a couple different types and decided to use the one with the higher rating. Well, what I didn't take into consideration was the friggin insulation (dumb ass). When I actually went to cut out the piece to wrap the kettle, and also a circular piece for the lid... I realized that choosing the one with the fiberglass insulation was a HORRIBLE idea. That shit got everywhere, and I was so pissed at myself. What a waste of $25. Well, I made it work for that first batch, but proceeded to throw it away right after. And the thing still didn't retain heat... it dropped 10 degrees in 45 minutes. WTF???

Second Option - Convert The Old Family Cooler.
This seemed very promising since a lot of people have done this, PLUS it would allow me to brew indoors during the winter which was a huge bonus. So, I needed to fix a crack on the inside, find the right size tube to fit through the hole, a stainless steel toilet supply line, and an in-line valve outside of the cooler to control the flow. Well, for the first attempt with this one, I decided not to fix the crack on the inside... it seemed sooo small and insignificant... big mistake. Well, maybe not big, but it did leak quite a bit through the course of mashing and lautering. The toilet supply line was easy, and finding the the valve setup locally was a little challenging but I got it worked out. I could've just snagged a valve from Northern Brewer... but I like to make things difficult for myself apparently. So, 2 1/2" (shanks) and a 1/2" valve switch later, I was in business. Since I had the leak, I tried caulking the outside of the hole, but that just slowed it down a little and made a gooey mess. Between my 2nd & 3rd batch, I got some food safe water sealant and sealed the shit outta the inside and out and it has worked wonderfully.

So, option #2 is the big winner for now... I do love my 10 gallon stainless steel kettles... and I hope to maybe make a 5 gallon version of the Brutus 10 someday with them. I have shitty burners, and smaller kettles, but I think it's possible. Just need to build the stand, get some pumps, and build the controller and I'll be set. I will still have the issue of heat loss with that effin thing, so we'll see. But for now, I'm loving the resurrection of my old cooler. We used to make a huge vat of jungle juice in that thing for parties, so it's probably loving this retirement plan. :-)

Cheers