How To Install a Weldless Bulkhead In Your Kettle

This is one of those jobs that just sounds intimidating – after all you can’t exactly un-drill a big hole in the side of your expensive brew kettle.  But it’s actually fairly simple if you have the right tools.

Unless you have welding equipment – or want to search around for someone who does – then weldless fittings are the next easiest option for the do-it-yourself-er.

You can piece them together yourself but the pre-assembled ones seem to be about the same price.  Once the bulkhead is installed then you can add on whatever device you want – thermometers, pick-up tubes, sight glasses, etc.

As for leaks – I’ve installed several of them and had no problems.  There are a few tips further down that will help you get a leak-free fit on the first try.

So what equipment do you need to install one then?

Tools:

1. Drill

2. Stepped drill bit

3. Cutting Oil

4. File set

5. Hammer and Punch

6. Ruler

7. Permanent Pen

8. Safety glasses and gloves!  There will be lots of metal shavings.

The stepped drill bit is the only tool you might not have used before.  Its cone-shape allows you to make a variety of hole sizes with a single bit.  You could also use a hole saw, but I think this is a better option.  They’re kind of expensive at the big-box stores.  But you can get a fairly cheap set at the discount tool stores – like this one at Harbor Freight – that will be more than adequate for this task.

You will also need a small bottle of cutting oil to lubricate and cool the bit.  Most hardware and probably some automotive repair stores will have it.  Don’t try this without it.

Step by Step

Standard Disclaimer: Using tools is dangerous.  Wear your safety gear.  Don’t get metal shavings or oil in your eye.

Start by measuring the location of the hole.  For a valve/dip-tube setup you want to get as low as you can but make sure you’re above the down slope on the inside of the kettle so that the whole thing fits flush against the kettle wall.

You might want to mount a thermometer a little higher up so that it’s out of the flame.  If you have a small volume kettle consider mounting the thermometer to one side of the valve.  This way probe is sure to be submerged even if the kettle is only partially filled.  Don’t forget to account for the size of the dial before you drill! You don’t want it to interfere with the valve when installed.

There’s probably some clever way to transfer the measurement to the outside of the kettle but I just eyeballed it.

Mark the spot with a permanent marker and then use the hammer and punch to make a small indentation.  This will keep the drill bit from wandering on you.

You could make a small pilot hole with a regular drill bit (use one designed for metal!) but I didn’t find it necessary.

Align the drill bit and go to town.  You’ll need a fairly high speed and a firm pressure to get things going.  Once you start to make a little progress stop and add a few drops of oil to keep everything from overheating.

It will take awhile to get the hole started but once you get to the stepped portion the whole operation goes quite quickly.  If you start to get any smoke stop and apply a bit of oil.

For a 1/2″ bulkhead you’ll probably need a 7/8″ hole but stop 1 or 2 steps early to test fit.  It’s easier to drill out one more step than to deal with a hole that’s too big…

When the hole is the correct size use your files to clean up any burrs.  Then and clean up the metal shavings and use a soap and water to clean off the oil.

Finally, install your bulkhead.  It really only needs to be hand tight and then maybe 1/4 to 1/2 turn with a wrench.  The little o-ring shouldn’t be deformed.  Over-tightening is a big source of leaks.

And that’s pretty much it.  Depending on what type of device you’re adding there will probably be a few more bits to thread together but the hard part – which wasn’t really that hard – is done!

Tagged as: drill, fitting, how-to, install, keg, kettle, weldless