1BBL Brewhouse build (garage conversion)

[fego]

Further progress...

To complete the false ceiling, I need to move a few things out the way. First up is my 'instant bar (patent pending)...

It folds flat to the wall...



...then drops and turns into a bar...



It's too high so needs lowering.



Was always a bit too high anyway....



I managed another sheet without moving the light but I later regretted this and should have moved it first...



I then cut out a frame for the loft hatch...



...quickly followed by another sheet with the hatch cut out...



I then used the cut out bit as a door and fitted it with cheap hinges and locks from Wilkos. This bit was trickier than I expected and the door was really heavy to work with but it worked a dream...



Then it was time for the end bit to go in...



followed by the gaps...



These were really difficult because there was nothing above to hold them up and the wall was a bit out meaning the bits I cut never seemed to fit. The light made it worse by both blinding me and also getting right in the way...



I created some false joists to screw into which held up the pieces and eventually finished it all, well the cold side anyways...



Next up was the rest of the hot side...



That was tricky too and there are plenty of little gaps that will need filling to make it air tight(er), but the temperature instantly improved when I fitted that last piece so I'm glad I did it...



Next up... the fermenting cupboard...

[Goosey]

keep going! (and posting!)

[willb]

Im so jealous

[Goosey]

I'll show you progress on mine once I've got a few more photos to make sense of it all. By the way, how do you state it's a 1 barrel brewery? Yes I understand that you have a 210 litre FV, but what if you had two? What I mean is, does this depend on how many lots of 210 litres you brew in a week? a month? etc? If I had five 100 litre FVs would that make me a 2 barrel brewery?

[pantsmachine]

How are you planning to deal with ventilation.

I'm going to play it by ear. Obviously I have the full garage door to open which should lose most of the steam, but that will put me on display to the neighbours. I've had a quick look at door curtains which might be useful, but as I say, I'll play it by ear first. There is a convenient wall in the hot side which could host a window or a vent fan but i'll look to solve that problem when I know what it is...

Garage door wide open works fine for me, The boiler is beside the door.i have been brewing out there for a few years and no black mould problems which would be 1st indication. Of course if i saw a discarded stainless extractor hood when i was at the dump then i might change my mind.

Closer to a 4 barrel brewery if we are going on 88 pints per barrel, sure it'll be a cracker whatever the size.

[Pinto]

Wonder how long it is before you get a friendly visit from the local constabulary ?? Im certain one of your neighbours will report your "illegal moonshine operation" at the first available oppertunity

[asd]

I'll show you progress on mine once I've got a few more photos to make sense of it all. By the way, how do you state it's a 1 barrel brewery? Yes I understand that you have a 210 litre FV, but what if you had two? What I mean is, does this depend on how many lots of 210 litres you brew in a week? a month? etc? If I had five 100 litre FVs would that make me a 2 barrel brewery?

My understanding is that however you work your mash tun or whatever, the final volume you deliver to your fermenter, in one go, in one batch, is the volume of your brewery. of course if you had a 1 barrel brewery, you could run it three times a day, and get three barrels a day out of it.

[floydmeddler]

Amazing!! It's coming together very nicely now

[fego]

...Closer to a 4 barrel brewery if we are going on 88 pints per barrel, sure it'll be a cracker whatever the size.

... how do you state it's a 1 barrel brewery? Yes I understand that you have a 210 litre FV, but what if you had two? What I mean is, does this depend on how many lots of 210 litres you brew in a week? a month? etc? If I had five 100 litre FVs would that make me a 2 barrel brewery?

I think there's some confusion here. We're talking brewers barrels which is the measurement of the brew length not the capacity per day/week etc. I have pots with a gross volume of 200 litres. These will be able to produce around 170-180 litres of wort per brew (mash) which after losses is about one brewers barrel (or BBL) of fermented beer which is 36 gallons/288 pints/165 litres or about 4 casks (firkins) of 72 pints/9 gallons/41 litres. I have 4x 100 litre and 4x220 litre fermenters so in theory can have 6BBL on the go at any one time if I cane the hot side. That's very, very unlikely to happen however and I only plan to ferment up to 170 litres and condition a further 170 at the same time maximum.

[JabbA]

What a great build, and thread! Doing all the work on your own too- well done that man! Keep the updates coming!!

Cheers,
Jamie

[fego]

Another update...

The limited space is continuing to hound me. I'm getting better at it but I still find myself permanently moving things out of the way to only be in the way again straight after forcing me to move it once again. This constant shifting means things keep going missing. I'm now on my 6th pencil for example and have misplaced a drill, screwdrivers and tapes for days on end. I even managed to lose a saw and my Stanley knife. Anyhoo, now that the false ceiling is up, I'm expecting things to become easier and as the Mrs. Fego is now getting fed up with the mess I have distributed 'everywhere' apparently, there's pressure to get going. Unfortunately, what with my family relying on me for hospital visits, doctors' appointments etc plus my real need to find permanent employment (in London), time to continue the build is scarce. Alas, however, I have made some further progress....

So, onto the fermenting cupboard. This is my working 'space'. I need to fabricate a frame then build two shelves into it, one of which needs to be removable so I have a choice of fermenting/conditioning vessels



I stack a lot of the kit as far out of the way as I can...



... and then get to measuring out the cupboard.



The trick here is to allow enough room to get the FV's in and for me to access them easily but also to allow for a double skin to include the insulation. Once I've convinced myself that the size is right and will allow for a comfortable hot side arrangement, I get on with making the frame. As the ceiling and wall are not level or parallel, this is awkward to get right but eventually I get along...



I decide to do the floor frame first and break two drill bits trying to get into the concrete. Once it's down, I start on the uprights...



I then complete the head frame and connect everything up making sure its all level...



This is from the hot side...



and a better view from the cold side...



I then create a quick stack of stuff to imitate what bottling preferences I have and therefore to start measuring up the shelf positions.



Right now, there still seems to be a lot to do before I'm anywhere near brewing but I'm happy nonetheless. I just wish I could find an electrician who can be arsed to give me a decent quote and want to help me. The sparks are definately my critical path to brewday #1...

[Belter]

I couldnt make it round this weekend. Ended up tied. Gutted I couldn't take you up on your offer of free beer

It's a shame it isn't in Cornwall as I'd give you a hand to do the electrics yourself. Kent is a little far and my tools are pretty heavy

[Titch]

stunning keep the pictures coming

inspires me to sort mine out

[dean_wales]

Jealous!

[fego]

A further update...

After an element of paranoid measuring up, I finally settled on how I want the shelves to work and where therefore they need to be fitted. Basically, I want the valve of the FV to be higher than the bottling taps so gravity can do its thing and I want the bottling taps high enough so I don't have to bend over when filling bottles. It looks like I can achieve this if I'm careful so I make sure I measure twice and cut once.







The measurements mean I have some flexibility including to ferment beer in 1x 220l FV or 2x 100litre FV's if needs be...





...or just 1BBL FV





Eventually, I stop over-thinking it and get on with fixing the shelf in...



...making sure it's level...



It is very strong and will easily support the anticipated weight. This is what it looks like...



Time now to start adding the skin. This involves more garage gymnastics to flick 8ft x 4ft boards around and cut them up. The first cut just wont go in from the cold side...



...so I take it round the hot side...and with a bit of guidance, it slots in...



I then set about cutting out the inners which inevitably don't fit first time and require just a 16th off like EVERY OTHER BLOODY CUT I'VE EVER DONE !!! GRRRRRRRRRRRRRRR.....



After more patience, I have a whole side complete but can't secure it in place because I need to put the insulation in first (which I haven't got yet)...



Also, I realise a flaw in my design which is that when I put the inside skin of the top half in place, it will cover up the ledge I was relying on to hold the top shelf up. This means creating a further ledge alongside it which means more measuring, cutting and levelling. School boy error that, but easily fixed.

Now, off to the builders' yard to get more stuff and where's that bastard electrician's number...?