Plastic Brewery Construction

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sstanier

Plastic Brewery Construction

Post by sstanier » Fri Sep 05, 2008 9:02 pm

Hi,

I started brewing not so long ago after perusing this fine forum. I began with a simple Coopers Bitter kit which has now conditioned and goes down rather unexpectedly well. Before I had even sampled that first brew I set my sights on brewing AG just to be able to do it from what are effectivel raw materials and to have more control over the style of my brew. So I have knocked up my own little 5G plastic brewery over the last few weeks and its nearly ready for its inaugural brew which I'm planning for a week on saturday, which I plan to be a simple hoppy Styrian Stunner. The plan was to keep costs low but to build a decent quality homebrewing setup and I thought it worth putting up a few pics of what I have knocked together.

Shopping List

3 x 33ltr bucket (£24 - LHBS)
1 x 25ltr bucket (£6 - LHBS)
4 x Wilkinsons Value Kettle (£32.00 - Wilkinsons)
20m Gaffer Tape (£2.29 - Wilkinsons)
3 x 15mm Peglers Ball Valve (£8.07 - Screwfix)
3 x 15mm Brass Tank Connectors (£3.27 - Screwfix)
1 x 15mm x 1/2" 90 Degree Male Brass Elbow (£1.69 - Screwfix)
3m of 15mm Copper Pipe (£5.41 - B&Q)
Pack of 90 Degree Copper Elbows (£3.99 - B&Q)
2 x 2mm Drill Bits (£1.99 - B&Q)
4 x 40mm Pipe Connector (£3.52 - B&Q)
4 x 40mm Pipe Terminator (£3.96 - B&Q)
10m of 10mm Soft Copper Pipe (£20 - B&Q)
1 x 8 1/2" Melamine Plastic Plate (£0.99 - Camping Shop)
3 x Camping Mats (£12 - Camping Shop)
Set of Hole Saws (£6.99 - Machine Mart)

Total - £136.67 (Give or take ~ Probably closer to £150 with all the odd little bits!)

So not the cheapest build by any means but i think the resulting kit should do a job!


HLT

Pic of the finished HLT, tap a la. Daab.

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Inside showing the twin elements and use of 90 degree elbows to reduce the deadspace to one litre.

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Shroud for elements made from 40mm PVC Pipe Connector and Termination.

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Pipe connector needed filing out to fit over the element body and then the termination i glued ino the tube to proide a watertight seal. The cable gland is used to pass the cable into the pipe connector shroud thingy! Makes a neat little job i think!

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Filled her up the other day and had a trial run and it doesn't leak! Phew!:D

Mash Tun

Pic of finished Mash Tun, isulated with three layers of camping mat and a load of gaffer tape.

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Inside showing false bottom made from Melamine plate. Deadspace measured at one litre also.

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Boiler

Pic of the boiler, which is exactly the same as the HLT except it has a copper manifold. Was a pain in the rear drilling all those holes. Tested for deadspace and found to be one litre also....so three litres deadspace in the whole setup which i dont think is too bad???

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And finally my nearly finished IC. Wrapped around a fire extinguisher and awaiting pipe connections.

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Left to do...

Still need to sort out a water connection for the IC. Have an unused washing machine connector in my flat's kitchen so i might utilise that....

Then just need to order my ingredients and it will be all stations go for brewday number one!!

Possibly in the future?

Dial Thermometers for Mash Tun and HLT.

Once i have a few brews under my belt and bottled i might look into a cornie or two....

Worth the effort?

Looking at the Hop and Grape website it seems you can get a ten gallon brewing for as little as £135 if you can forego an HLT, so what I have knocked up here is a little expensive but it was nice to knock up my own gear as well as hopefully my own beer! Plus given that I live in a flat the size of a rabbit hutch it's size is more appropriate than the Hop and Grape setup. What do all you think?

Will post next week some pics of my first AG brewday....wish me luck! :lol:

adm

Post by adm » Fri Sep 05, 2008 9:16 pm

I think you've done a sterling job! Good work.

I hemmed and hawed when I started AG (all of 2 months ago) and then decided to buy the H&G 10gal kit rather than build my own as I don't have a huge amount of free time. I think it was about £160-170 by the time I had a double element and an IC.

The main benefits I see to your set up are that you've got the dedicated HLT and you've got nice ball valves on everything ( I hate the orange screw tap on the H&G boiler and will change it to a ball valve soon)

Also, if I was doing it again, I would make my own IC. The H&G one is good, but it's quite small - my next one will be designed to maximise the use of space in my boiler.

On the plus side for the H&G kit, it's serving me well and the 10G vessels give me room not to worry about boilovers, and also to be able to do an 8G brew if I want to fill 2 cornies. I wouldn't like to try 10G with it though as it would all be uncomfortably full. I have also proven today that the max grain bill you can fit into the H&G mash tun is 10Kg, so my first upgrade on the path to all shiny will be a Nordic Optical thermo box mashtun!

I'd like a dedicated HLT, but right now I brew in my kitchen and don't really have the space for it and using the boiler as the HLT works well, but entails a bit of bucket jiggling. Once I get my garage construction work finished, I'm going to relocate to the garage and set up the brewery semi permanently - at this point I'll probably go to a shiny boiler and use the H&G one as the HLT.

Anyway ....enough talk, great job on the kit. Now go and get it dirty!

jonnyv

Post by jonnyv » Fri Sep 05, 2008 9:31 pm

Bloody good job! =D>

The only improvement I can suggest is insulating your HLT... It reduces the time spent heating up strike/sparge water. It's on my to-do list for my HLT.

Damfoose

Post by Damfoose » Fri Sep 05, 2008 9:44 pm

Sterling job their mate.
Its making me more and more likley to start getting my kit built as soon as I can but by the looks of things im going to be on a daily commute to York in a few weeks until Christmas :(

sstanier

Post by sstanier » Fri Sep 05, 2008 9:48 pm

ouch...not sure i would fancy the commuting!

i doubt it will take you long to knock your own up, i would guess it took me a couple of days to knock this lot together, which is no time compared to the countless hours i spent musing over what bits were needed whilst browsing this forum! :?
Last edited by sstanier on Fri Sep 05, 2008 9:56 pm, edited 2 times in total.

mysterio

Post by mysterio » Fri Sep 05, 2008 9:48 pm

Nicely thought out, good job mate.

Looking forward to the inaugural brewday pics!

maxashton

Post by maxashton » Sat Sep 06, 2008 12:04 am

Excellent work.

Vossy1

Post by Vossy1 » Sat Sep 06, 2008 12:24 am

Tidy gear sst, now get that fine brew on :lol:

Particularly like the element shrouds 8)

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jamesb
Hollow Legs
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Location: Wrexham

Post by jamesb » Sat Sep 06, 2008 1:29 am

You clucking fastard.

Love it. I did mine bit by bit and it's nowhere as complete as that (although I have shiny boiler!)

May all your brews turn to gold. Or porter. Or stout.

[Just got back from Shrewsbury BF. A bit worse for wear]
James

"When you have lost your inns, drown your empty selves, for you will have lost the last of England."
Hilaire Belloc, Preface to The Four Men (1911) ...

coatesg

Post by coatesg » Sat Sep 06, 2008 1:46 am

Kit looks brill - false bottom on the tun looks excellent; and gotta love those Wilkos/Tesco elements :wink:

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Jim
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Location: Washington, UK

Post by Jim » Sat Sep 06, 2008 8:00 am

Excellent work, SS. 8)
NURSE!! He's out of bed again!

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Bru4u

Post by Bru4u » Sat Sep 06, 2008 8:01 am

Nice Job, well done.
It gets a bit adictive don't it :wink:

prolix

Post by prolix » Sat Sep 06, 2008 11:04 am

Good stuff mate will be worth every penny when you sup that brew and know you made it!

Love the shrouds by the way will have a look at making something similar always worried about them and boil overs.

Buzz

Post by Buzz » Sat Sep 06, 2008 11:38 am

Nice work indeed 8) Regardless of the cost compared to buying one, the fact that you built it will add so much satisfaction to the end result.

ADDLED

Post by ADDLED » Sat Sep 06, 2008 11:52 am

Hey lovely setup SS, very neat work.
Are those ball valves compression fit?

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