BeerBorg

Here's a really long post documenting the build of my Dual 120V Recirculating eBIAB rig:


I'm using P-J's 2-element 120V diagram from HomeBrewTalk:


For my build, I'm using a 62qt Bayou Classic SS Pot with a steamer basket, all SS camlock fittings from BargainFittings, a GreatBrewEh pump, and DudaDiesel 20-plate chiller. For the control panel, I'm using the Auber project box, SYL-2352 PID, and a mix of switchgear from Auber and eBrewSupply. For heating elements, I'm using 2000W SS elements from BostonHeatingSupply.

Plumbing diagram:



A few photos of the build:

Front panel punched:


Modifications to the back (actually ended up flipping the handy box around later):


Trial fitting the insides:


Contactors and terminal strip mounted; e-stop on top:


Starting to wire:


All wired! Ready to button up:


And here are the finished pictures. Tested all functions with a light bulb - everything is working!

It's Alive!!!


From the back:


And a side view:


Later, I added a cooling fan to the heatsink as it was getting pretty hot:


Kettle modifications:

Kettle punched!


View from the inside:


Bulkhead and ball valve installed:


One of the elements' mounting boxes:


Had to plug an extra hole that I decided not to use:


Everything is mounted and leak-tested! There's another element box on the other side:


And that's what inside looks like:


I waterproofed element boxes with silicone.

Wiring the elements.


The kettle is complete. Pardon the dust.


An "over the side" whirlpool arm:


A couple shots of my system in action:




And here's the parts list for my build for anyone wanting to duplicate this system. Quantities noted where applicable.

Amazon.com

62 qt Bayou Classic SS Kettle with basket (actually bought used, but Amazon has the best deal on them)
US Wire 65050 12/3 50-Foot SJTW Orange Heavy Duty Extension Cord
AC Infinity LS9225A-X Standard Cooling Fan

eBrewSupply.com

220v 40a, 110v Coil, Contactor qty:2
40a Solid State Relay SSR qty:2
2-Way, 1 NO Contact, Switch
Mushroom Button, NO Contact
Flashing Buzzer
Add on NO Contact

BargainFittings.com

NEW - KEG Weldless Bulkhead Kit
- Inside the vessel fitting STREET 90 - 1/2" NPT
- Valve 2 - piece SS ball valve
- Hose Barb (valve outlet) <NONE>
1/2" SS Camlock F style fitting Quick Disconnect qty: 3
1/2" SS Camlock D style fitting Quick Disconnect qty: 1
1/2" SS Camlock B Style Quick Disconnect qty: 4
1/2" SS Camlock A Style Quick Disconnect qty: 2
1/2" NPT SS 2 piece ball valve qty: 1
1" Stainless Locknut and o-ring kit qty: 2
Weldless thermometer sight gauge kit
- Vessel: Keg or kettle
Silicone Tubing 1/2" ID x 3/4" OD qty: 12 ft
1/2" SS Camlock Dust Cap Style Quick Disconnect qty: 1

BrewHardware.com

Mash recirculation tube w/camlock
Sight glass calibration decals

eBay.com

2 x Panel Mount Fuse Holder For M205 5x20mm Fuses
10PCS Metal Film Resistor 1 Watt 1W 1K ohm
10 Pcs 5x20mm Quick Fast Blow Type 1A 1 AMP 110-240V Glass Tube Fuses
Aluminum Large Rectangle Heatsink

Auberins.com

1/16 DIN PID Temperature Controller (SSR control output)
Item #: SYL-2352

Illuminated Maintained Pushbutton Switch, 2 NO, 22mm. 120/240V qty: 2
Item #: SW1 LED Color Option - Green

Illuminated Maintained Pushbutton Switch, 2 NO, 22mm. 120/240V qty: 2
Item #: SW1 LED Color Option - Blue

Liquid tight RTD sensor, 4 in, 1/2 NPT Thread
Item #: PT100-L100NPT Cable Option - Deluxe Cable

Box for 1/16 DIN controller
Item #: Pbox16

McMaster.com

Multipurpose Silicone Adhesive/Sealant 2.8 oz Tube, Translucent
18-8 Stainless Steel Wide-Rim Shim .075" Thick, 1-1/2" ID, 2-1/4" OD qty: 2

BostonHeatingSupply.com

Rheem SP10868GL 120V 2000W Stainless Steel Element qty: 2

GreatBreweh.com

Brewery Pump

DudaDiesel.com

B3-12A 20 Plate Beer Wort Garden Hose Chiller

Menards

4" x 2" Handy Box Extension qty: 3
4" x 2" Handy Box Cover, Blank qty: 4
3/8" Romex Connectorm 10 pcs
1" Romex Connector
Plug Straight Blade 20A, 125V qty: 4
20A Commercial Grade Outlet
Terminal Block, 6 Pole
1/2" copper tubing
90 degree 1/2" copper elbows qty: 4
Plumbers Silicone Tape
5/8" x 25' Medium Duty Garden Hose

Harbor Freight

520 Piece Terminal Set
127 Piece Heat Shrink Tubing Set
100 Piece Zip Ties

Very nice! I'm looking to add a bulkhead and sightglass to my BK. Did you use a step bit for those holes, or something else?

gwcr wrote:Very nice! I'm looking to add a bulkhead and sightglass to my BK. Did you use a step bit for those holes, or something else?

A step bit to make a 1/2" hole, and then a 1/2" knockout punch from Harbor Freight (which is really 7/8"). Makes a super clean hole. You can use a step bit and clean up the edges with a dremel too. Lots of ways to skin a cat.

WOW! That's all I can say... WOW, what a rig!

Russki: What was your total cost of parts for this unit? What was your labor cost (what you think your labor is worth)? Now I think you have found a side business / hobby for the brewing community...LOL

T8rSalad wrote:Russki: What was your total cost of parts for this unit? What was your labor cost (what you think your labor is worth)? Now I think you have found a side business / hobby for the brewing community...LOL

I think I was somewhere around $850 or so all said and done for parts. Labor-wise... probably 10-12 hours altogether. Considering similar complete systems are selling for around $1000-$1100, margins are pretty slim... I'd rather keep this as a hobby, and make money doing my day job!

russki wrote:

gwcr wrote:Very nice! I'm looking to add a bulkhead and sightglass to my BK. Did you use a step bit for those holes, or something else?

A step bit to make a 1/2" hole, and then a 1/2" knockout punch from Harbor Freight (which is really 7/8"). Makes a super clean hole. You can use a step bit and clean up the edges with a dremel too. Lots of ways to skin a cat.

Yep there sure are. Just stick a finger or two down the mouth hold it up and give the tail a good hard yank.....................

Glad to see this thread up again Russki THANKS!!!!

Question about the recirculating wort coming in through the top, does it go below the waterline or is it being sprayed out over the mash?

Edit: just saw the other thread about using some sort of return arm that runs below the water line.