dr_bob wrote:However, I've faced another impasse - the Hop and Grape immersion chiller - even with 7 gallons in the boiler, the chiller barely touches the water when hooked onto the side of the barrel, and suspending it in the middle of the boiler runs the risk of the water connections working loose right in the middle of the wort...
I had exactly the same issue!

I bought the 10 gallon brewery and never thought about the pipes going uber-soft when I chucked the whole lot into the boil. Result was water spraying all over the place! Not really what I wanted but I guess it helped cool the brew.

In this emergency situation I reduced the water flow to a point where it wasn't pissing out all over the place.
Took me about 30 minutes to cool it in this manner but doesn't seem to have had a detrimental effect on the finished product. I'm going to buy some jubilee clips and tighten the pipes on for the next attempt. I may need to buy some piping that's happy with boiling temperatures for doing 5 gallon brews in a 10 gallon boiler eventually but for a £1 or so I'll try the clips for now.
