The box has foam insulation between inner and outer wall but the lid was hollow.
I drilled 6.5mm holes in the lid at varying positions and then injected expanding foam into until it came out of the holes. This was trimmed when dry and the hole sealed with masitc.
Next I had to cut a hole, centrally and as low as possible in the side of the cool box to accommodate a tap. Being very careful not to cut into the inner wall. I used a lock hole cutting adapter on my drill. The centre punch came through the interior wall into the cool box and I could use this to cut the hole more accurately in the inner wall to fit the tap
Tap fitted
Next I created the manifold. This is made of 22mm copper pipe, 4 x 22mm corners and a 22mm to 15mm reducer tee piece. The manifold had to utilise the entire surface area of the box but remain 1/2 an inch fron the sides.
First I cut the copper pipe to length.
Then at 1/2 inch intervals I cut halfway through the pipe along its entire length, and then assembled the manifold. The joints do not require soldering, just push fit together.
I then attached the manifolds to the tap using a section of clear pvc piping.
I then had to drill a 6.5mm hole centrally in the lid to take the sparger.
Then I pushed the sparger through the lid and the job is a gooden.
I will have to test the temperature holding capabilities of my new mash tun, though I'm sure it will be fine.
I know this has been covered before by full malty, but I thought I'd show the process in glorious technocolour
EDIT
I have now changed the tap for an all metal construction. I did this primarily for a more sturdy set up. I use a standard 15mm tank plug, compression fittings and a 15-10mm radiator valve. The 10mm is just the right size for my tubing
:blink:
