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DIY Conical Build Pt 1 The Materials

The foundation material for the conical needs to be stainless steel in order to keep the vessel from rusting.  Now for grade of stainless – something like 304 or 18/8 which is used for stainless pots and buckets should be just fine and is fairly common.  With that determined what options exist for us to get that material at reasonable cost.  Well, free is obviously best, but since I used up much of my pile of salvaged stainless steel sheets (mainly BBQs) building the wood fired pizza oven I don’t have much of that left.

Then there’s the buy option, and actually as I am going forward I find myself buying some stainless material for the legs – but now that I consider it I could have gotten away without making that purchase, but more on that once we get to that stage of the build…

Materials with which to build the DIY Conical

Materials with which to build the DIY Conical

Anyway back to the fundamental parts of the conical – the vertical segment and the cone.  Well since the top is basically like a pot without a base I thought I might as well go that route and build it out of stainless steel pots which are readily available and low cost.  As an added bonus the top segment is already nicely rolled and sealed.

Now some folks I’ve seen building conicals use a cone made from spun stainless funnels – but since I couldn’t find one easily and at low cost I figured I would just form one up from some more stainless steel sheet (or pot bits).  It’s more welding but I kinda want the practice to improve my skills so really not all that bad.  Plus as indicated before – by brewing in the conical with the associated 90 minute boil I would be able to achieve excellent sanitation even where weld imperfections might otherwise thwart chemical cleaning.

Now for the disadvantages… well these pots are pretty thin – definitely thick enough to do the job without problem but thinner material is often more difficult to weld effectively. Still cost and availability prompted me to consider this my best option – especially since I was reasonably sure that I would be able to handle the welding of the think stainless with the Henrob OA torch based on my experience with the stainless pizza oven.

The price – well a pot set from Harbor Freight where the largest pot is 4 gallons cost me $20 and and a 5 gallon pot at the local homestore cost me another $20.  Now some folks I’ve seen building conicals use a cone made from spun stainless funnels – but since

Now for the cool part right – the triclamp fittings that make the conical so versatile.  Well, these are available at low cost off ebay or amazon from manufacturers in China.  How low cost is low cost?  Well a 1.5″ weld-on tricalmp fitting runs $1.99 with free shipping!  So I purchased a bunch of 1.5″ fittings, gaskets, caps, threaded fittings, valves and the like along with a few 2″ fittings to allow me to pass the electrical heating element into the conical.

Total cost for the bits and bobs… slightly over a hundred bucks.  Not bad for a prototype.

 

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DIY Conical Fermenter and Brewing System on the cheap

I’ve been brewing beer at home for quite some time – since before I could legally drink what I was producing.  Much of that has been from kits or from malt extract and my homegrown hops in large part because of the ease with which that can be accomplished.  When I’ve gone over to the all grain side it’s been with cobbled together motley collection of coolers, strainers, bags and the like – which all things considered has gone pretty well.

Recently I’ve wanted to increase my all grain brewing in part because it offers more control but truth be told because it also promises to be significantly cheaper since malt extract and kits are now getting to the price point they produce beer for half the price of purchased product.

DIY Conical Fermenter and Brewing system beside a 3 gallon keg

DIY Conical Fermenter and Brewing system half completed beside a 3 gallon keg

In my review of the systems that are out there I’ve been drawn to the one vessel systems – either the brew-in-a-bag systems, or the brew in a single vessel like the braumeister out of Germany or the more recently introduced grainfather – which really resembles a large commercial coffee urn.  But the one that really caught my fancy was the system that has you brewing in a single vessel that vessel being a conical – now that is efficiency!

I’ve wanted a conical for some time now, and since I’ve started to get a hang of welding stainless steel with my Henrob oxy-acetylene torch when I built the stainless steel pizza oven I wanted to give it a try – but since my welding isn’t exactly commercial grade the idea of doing a 90 minute boil in the conical – which would sterilize the nooks and crannies left in my imperfect welds that might be otherwise hard to get clean – efficient and able to accommodate my stainless welding limitations.

Because I didn’t want to invest too much money into the project I decided to start with a few cheap stainless steel pots – a four pot set from harbor freight, the largest one a 4 gallon unit, and an additional 5 gallon pot.  Both the set and the larger pot were nineteen bucks each.  Tri-clamp fittings from e-bay, direct from China added another $40 or so, toss on a pound of stainless tig rods and we’re looking at about a hundred bucks.

Now, I’m frugal, but one of the other factors here is that this is a prototype, and as such it won’t be perfect, so it doesn’t make sense to dump a lot of cash into something that inherently will be less than the optimal design.

The other thing is that this won’t handle a full five gallon batch – but it should be sized right for three gallon batches, which if this system is as easy to use as I would like to make it is about the perfect size for turning out loads of different beer variations.

Oh, and I’ve got a twist up my sleeve that I’m going to explore, but I’ll save that for later.  Stay tuned to see how it works out.